BMW E60 User manual

Subject Page

E60 Complete Vehicle

Objectives of the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Purpose of the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Brief History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Highlights and Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Vehicle Data Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Front Bumper System

Removing and Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Rear Bumper System

Rear Light Clusters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Removing and Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Luggage Compartment and Door Attaching Hardware

Hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Exterior Door Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Table of Contents

E60 Complete Vehicle

Initial Print Date: 08/03 Revision Date: 09/03

E60 Complete Vehicle

Model: E60 - 525i, 530i, 545i

Production: Start of Production MY 2004

This intent of this workbook is to assist you with diagnosis and testing in addition to the

detailed information found in the the latest Diagnosis and TIS of the DISplus/GT1.

This section will be instructor led for a brief review of the E60 Complete Vehicle. You are

encouraged to use this workbook with the latest Diagnosis and TIS information to make

notes during diagnosis and testing of the nneewwccoommppoonneennttss//ssyysstteemmssoofftthheeEE6600..This will

be valuable to you as supplementary information or a memory refresher when performing

diagnosis in the future.

NNoottee::For more in depth and detailed information about the E60 Complete Vehicle, refer to

the ST046 E60 Complete Vehicle training CD.

For additional and updated information, always refer to:

www.bmwcenternet.com

- Diagnosis and TIS information/updates

- Service Information Bulletins

- DCS messages

Objectives:

After completion of this module you will be able to:

• Properly remove, install and adjust the front bumper system

• Properly remove, install and adjust the head lights

• Properly remove, install and adjust the rear light clusters

• Properly remove, install and adjust the rear bumper system

• Properly remove and install the exterior door handles

E60 Complete Vehicle

Purpose of the System

The E60 is the fifth edition of the BMW 5 Series replacing the E39. The automobile revo-

lution in design and engineering initiated by the E65/E66 now finds its logical continuation

in the E60. Virtually all the significant innovations of the 7 Series are also offered in the 5

Series.

However the E60 also offers new features of its own, some of which will make their appear-

ance in other model series in due time. The most important of these new features are:

• Active steering system, whose variable reduction ratio adapts itself to the relevant driving

situation.

• Lightweight design with a front-end structure of bonded and riveted aluminum (GRAV).

• Head-up display, which projects the most important information such as vehicle speed

or navigation arrows in the form of a virtual image directly into the driver's field of vision.

• Adaptive directional headlight system, which adapts itself continuously to the steering

angle and thus illuminates the approaching bend.

BMW 5 Series - Brief History

ThheeEE1122

The first BMW to be christened the "5 Series" was the E12.

In 1972 this model in the form of the "520" began the system

of model designation which has remained to this day: The

first number stands for the model series, while the second

and third numbers represent the cubic capacity.

A total of 702,242 E12s from the 518 to the 535i were pro-

duced in Dingolfing and Munich until 1985. KT-9494

E60 Complete Vehicle

ThheeEE2288

The successor model E28, which at first glance appeared to

have only minor modifications, brought the production fig-

ures to 723,001 with the model designations 518i to 535i

between 1980 and 1990.

From January 1983 production of the 5 Series - with the

exception of the M5 offered for the first time - was confined

exclusively to Dingolfing. 1983 was also the year when the

524td became the first 5 Series to feature a diesel engine.

ThheeEE3344

The 3rd generation 5 Series registered a major increase in

production volume: Between 1987 and 1996 a total of

1,330,661 E34s came off the Dingolfing production line. The

engine range of four- and six-cylinder models was extended

to include a V8 (518i to 540i) and rounded off by diesel

engines (525td and 525tds) and the high-performance M5.

A second bodystyle was also introduced in the form of the 5

Series touring, which also included a version that ran on liq-

uefied petroleum gas (518g touring). A four-wheel drive was

also produced in both saloon and touring versions in the form

of the 525ix.

ThheeEE3399

The current 5 Series was launched in 1995, of which to date

1,362,884 have been built (as at: 30 September 2002). In

addition to the standard saloon and touring, there is also a

safety saloon version of the E39 (540i Protection).

The engine options available range from the 518i to the 540i

(diesel: 520d to 530d), as well as the M5.

KT-9490

KT-9489

KT-9473

E60 Complete Vehicle

The new E60 - Highlights and Design

The BMW Group's new design strategy with its broadening of the family resemblance lends

future BMW model series still more individual character. It is thus possible for the E60 to

embody the values of the 3 Series (dynamic and sporty) as well as those of the 7 Series

(successful, top of the range and sporty) and yet remain an individual and original car with-

in the scope of traditional BMW model series.

Unlike its competitors - and also its predecessors at BMW in previous years - the new 5

Series demonstrates its own clearly recognizable lines: The unique character of the individ-

ual model series within the overall range of the BMW marque will in future be increasingly

accentuated. The new 5 Series therefore comes across neither as a small 7 Series nor as

a big 3 Series.

The front end makes a bold and dynamic state-

ment.

The most striking features are the new twin

headlights and the dramatically sloping hood

lines on both sides which now already begin at

the level of the earlier swage line.

Flowing lines run from the headlights along the

sides to the rear end of the E60.

KT-11013

KT-11012

E60 Complete Vehicle

The side line is a logical extension of the front-end design. Thus the E60 is the first BMW

model not to have the previously typical side swage line. Its place is taken by a character

line, an edge of light which lends the side view a whole new character. Various light reflec-

tions above and below this line produce a play of light and shadow, thereby giving the

impression of a very low side panel.

The transition from the hood to the side panel occurs in the imaginary extension of the

character line. TThhuusstthheeEE6600hhaasstthheelloowweessttffrroonntteennddeevveerrooffaannyyBBMMWW.. The sculpture-like

appearance of the side view is consolidated by the fact that there are no protective strips

in the door areas.

Despite its increased height, the passenger cell has a coupe-like appearance thanks to the

sweeping design of the C-pillar. Short overhangs and generously dimensioned wheel arch-

es accentuate the dynamic, bold overall appearance. The clear shaping of the wheel lips

as a typical BMW design element emphasize the wide track of the E60.

The rear end conveys an at once wide and compact effect due to the fact that there are no

visible joints. Under the high deck lid with integrated spoiler lies tthheebbiiggggeessttlluuggggaaggeeccoomm--

ppaarrttmmeennttiinntthheeccuurrrreennttBBMMWWrraannggee.. The rear lights are mounted in brilliant optical hous-

ings, the tops of which are sloping in appearance.

The large rear apron of the E60 is subdivided by additional reflector elements and thus

gives the impression of being lighter.

A distinctive diffuser lip not only ensures opti-

mum aerodynamics but also reduces the

amount of dirt which accumulates on the vehi-

cle rear end.

The overall impression communicates an

unmistakable sense of the E60's power and

strength to road-users driving behind it.

KT-11014

KT-11016

E60 Complete Vehicle

System Components

Body Structure

The body dimensions have been increased to improve roominess in the rear compartment

(+ 5 cm knee room) and to increase the luggage compartment capacity (at 520 L the largest

capacity of all the BMW vehicles including the E65).

In order to make the E60 signifi-

cantly lighter than the current 5

Series, BMW designed a

"reduced-weight aluminum front

end" (GRAV).

The front end consists almost

entirely of aluminum while the

transition to steel occurs in the

front bulkhead area. Aluminum

components are shown in darker

shaded (front clip) section.

The weight saving at the front end not only reduces the total weight of the vehicle but is

also a significant factor in the E60 attaining the ideal axle-load distribution of 50/50.

On the one hand, an aluminum body sec-

tion offers reduced shielding against

external electrical radiation, making it nec-

essary for separate shielding of the wiring

harnesses and electronic control units.

On the other hand, riveted and bonded

aluminum components do not always

provide a guaranteed circuit to ground.

This results in individual front end compo-

nents being connected (in production)

with small EMC safety weld seams and in

the event of repair, with grounding straps.

1. Spring Support

2. Engine Support

3. Bulkhead carrier support

4. Outer connection (steel)

5. Bulkhead Cross Member

6. Bulkhead

7. Inner A-pillar (steel)

KT-11776

KT-11777

E60 Complete Vehicle

The transition from the aluminum front engine

support rail to the steel rail section joint (connec-

tion) is produced by bonding and punch riveting.

To increase conductivity, ground points are locat-

ed on the two rails and are connected with a

ground strap.

In addition to the underhood strut tower V- struts

(2 lower left), the bumper carrier (1 lower right)

and thrust panel (2 lower right) provide addition-

al reinforcement and structural rigidity.

NNoottee::TThheeVV--ssttrruuttss,,bbuummppeerrccaarrrriieerraannddtthhrruussttppaanneellm

muussttbbeeiinnssttaalllleeddaannddpprrooppeerrllyyttoorrqquueedd

beeffoorreetthheevveehhiicclleeiissddrriivveenn..IIffnnoott,,tthheerriiggiiddiittyyoofftthheeffrroonntteennddwwiillllbbeeccoonnssiiddeerraabbllyyrreedduucceedd

lleeaaddiinnggttoonnooiisseeaannddssttrruuccttuurraallddaammaaggee..

The crash box is a deformation element

specially developed for the E60.

The crash box is part of the side frame and is

secured at the bottom of the A-pillar.

In the event of a frontal crash, the crash box

absorbs forces that are transmitted via the front

wheel into the side frame in the sill area.

KT-11777

KT-11832

KT-11836

KT-11780

E60 Complete Vehicle

The E60 also integrates the familiar side impact

protection gards (steel).

These are bolt on parts that must be replaced

when damaged.

Body Repair

Repairing an aluminum body requires completely new repair methods in body shops with

properly trained personnel, as well as proper tools and equipment.

Aluminum materials can not be “stretched”, this rules out the possibility of pulling on a

straightening bench. Components deformed as a result of an accident mmuussttaallw

waayyssbbee

reeppllaacceedd, which incurs more extensive training, tools and assembly procedures than is the

case with steel bodies.

Using the frame rail as an example, deformed E60 aluminum components must be cut off

at permanently defined points and replaced by new components.

Special insert repair elements made of aluminum

are required to ensure that the replacement parts

are safely and securely held in place.

The insert element for repairing aluminum (top

left) is inserted into profile chambers and then

expanded into place by bolts (refer to the E60

SIP for more details).

NNootteess::

KT-02600

KT-9495

E60 Complete Vehicle

Vehicle Data Views - Heights / Widths / Door Angles / Turning Circle

02556_02

Ø11.6

3488

3761

Ø12.3

68°

02555_02

1469

1443

1558

1840

1578

2046

10101036

Table of contents

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