Table of Contents
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Table of Contents
E60 Complete Vehicle
Subject
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
Removing and Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Rear Light Clusters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Removing and Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Exterior Door Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Initial Print Date: 08/03
Revision Date: 09/03
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Summary of Contents for BMW E60
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Page 1: Table Of Contents
Table of Contents E60 Complete Vehicle Subject Page E60 Complete Vehicle Objectives of the Module ........2 Purpose of the System . -
Page 2: E60 Complete Vehicle
N N o o t t e e : : For more in depth and detailed information about the E60 Complete Vehicle, refer to the ST046 E60 Complete Vehicle training CD. -
Page 3: 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. - Page 4 E39 (540i Protection). The engine options available range from the 518i to the 540i (diesel: 520d to 530d), as well as the M5. KT-9473 E60 Complete Vehicle...
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Page 5: 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. - Page 6 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.
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Page 7: System Components
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-... - Page 8 . . 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.
- Page 9 , 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.
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Page 10: Vehicle Data Views
Vehicle Data Views - Heights / Widths / Door Angles / Turning Circle 2046 1036 1010 1578 1558 1840 02555_02 Ø11.6 Ø12.3 02556_02 E60 Complete Vehicle... - Page 11 Vehicle Data Views - Lengths / Heights / Hood - Luggage Comp. Angles / Overhang Angle 2888 1100 4841 02557_02 E60 Complete Vehicle...
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Page 12: Technical Data
Unladen weight as 530i (kg) 1606 1570 (545i = 1695) Maximum load as 530i (kg) Fuel tank capacity L (gal) 70 (18.5) 70 (18.5) Technical Data - E60 E60 Model Variants (US) 525i / 530i 545i Engine M54B25 / M54B30 N62B44... - Page 13 Technical Data - E60 (continued) E60 Model Variants (US) 525i /530i 545i Maximum engine speed (rpm) 6500 6500 Manual transmission (6 spd) GS6-37BZ GS6-53BZ Automatic transmission (6 spd) ZF GA6HP19 ZF GA6HP26 Final Drive Ratio (:1) 2.93 (M) 3.38 (A) 3.15 (M) 3.73 (A) / 2.93 (M) 3.46 (A)
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Page 14: Front Bumper System
Re e p p l l a a c c i i n n g g t t h h e e K K i i d d n n e e y y G G r r i i l l l l e e • The bumper trim panel must be removed in order replace the kidney grille. E60 Complete Vehicle... - Page 15 : : KT-10894 1. Top connecting plate 4. "V" brace 2. Top mounting bracket 5. Side supports for bumper trim panel 3. Lower side panel bracket E60 Complete Vehicle...
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Page 16: Headlights
The high beam headlight function is performed by an H7 long-life bulb in each of the inner reflectors. The flash to pass simply uses the high beam light only. KT-71003 E60 Complete Vehicle... - Page 17 In each inner reflector there is an H7 long-life bulb, which is used for the flash to pass function. KT-71003b N N o o t t e e s s : : E60 Complete Vehicle...
- Page 18 • For installation, the headlamps must first be adjusted and aligned with the side panels (slides in adjustment slots with bolts loose, up/dn adjustment by a threaded mount). The bumper trim panel is then aligned to the headlamp units. N N o o t t e e s s : : E60 Complete Vehicle...
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Page 19: Rear Bumper System
- Brake Force Display. To improve the reaction of other drivers in a panic stop, the E60 has a Brake Force Display System. If an extreme deceleration rate or ABS signal is detected, the bulbs will receive the full 21 Watts of power and the brake light plus Brake Force Display function is illuminated. -
Page 20: Removing And Refitting
• Install the rear lamp units and align with the luggage compartment lid and the side panels. N N o o t t e e s s : : E60 Complete Vehicle... - Page 21 R R e e c c o o r r d d t t h h e e s s t t e e p p s s a a n n d d f f a a s s t t e e n n e e r r s s r r e e m m o o v v e e d d d d u u r r i i n n g g t t h h o o s s e e s s t t e e p p s s a a s s y y o o u u r r e e m m o o v v e e t t h h e e r r e e a a r r b b u u m m p p e e r r s s y y s s t t e e m m : : E60 Complete Vehicle...
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Page 22: Luggage Compartment And Door Attaching Hardware
1. Door attachment plate, front door hinge 2. Door attachment plate, rear door hinge 3. Hinge brace plate (attaches to B-pillar), rear door 4. Hinge brace plate (attaches to A-pillar), front door KT-10957 E60 Complete Vehicle... -
Page 23: Exterior Door Handles
R R e e m m o o v v e e t t o o o o l l , , r r e e l l e e a a s s e e d d o o o o r r h h a a n n d d l l e e . . 512220 E60 Complete Vehicle...
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