Part 1

00 02 03 (052)
Complete vehicle
E60, E61





Highlights in brief
The BMW 5-Series, with the saloon (E60) and the Touring (E61), presents a sporty, elegant and stylistically new upper mid-range. A sophisticated overall engineering concept achieves high performance in conjunction with low consumption, and a perfect axle-load distribution. The new composite construction of the body reduces weight: the innovative combination of aluminium and steel actually increases space and comfort.
The systems described in brief in this document are as follows:

- Body
- Design
- Interior
- Front end

- Electrics/electronics
- Vehicle circuit structure
- Power supply
- Car access system
- Central locking system
- Wipe/wash system
- Exterior mirrors
- Power windows
- Sliding/tilt sunroof
- Panorama glass sunroof
- Automatic opening and closing of the tailgate
- Anti-theft alarm system
- Passive safety system
- iDrive, central information display and controller
- Head-up display
- Instrument cluster
- Adaptive headlights
- Integrated automatic heating and air-conditioning system
- Park Distance Control
- Information and communication systems
- Condition Based Service

- Suspension
- Aluminium suspension
- Active Front Steering
- Dynamic Stability Control
- Dynamic drive
- Runflat indicator
- Tires with emergency-running characteristics (run-flat tires)
- Self-levelling suspension

- Power plants
- Engines
- Transmission
- Sequential manual transmission
Some of the topics are dealt with in detail in the BMW Technical bulletins stated.
Body
- Design
The body, the decorative grille and the twin headlights of the E60 and E61 have been redesigned. Lighted optical-fiber bars above the headlights and the familiar parking-light rings provide a new, unmistakable design.







The rear lights of the E60 are one-part light clusters. The rear lights are integrated into the side walls. The tail lights consist of the:
- turn signal lights
- two-stage brake lights
- tail lights
- rear foglight (not on US version)
- reversing light





Rear lights, E60

The rear lights of the E61 are two-part light clusters. One part is integrated into the side wall. The other part is integrated into the tailgate. The rear lights in the side wall comprise:
- turn signal lights
- two-stage brake lights
- tail lights
The rear lights in the tailgate comprise:
- rear foglight (not on US version)
- Reversing light





Rear lights, E61

The E60 and E61 are also equipped with two-stage brake lights. The purpose of two-stage brake lights is to tell the driver of the following vehicle how sharply the vehicle in front is braking. The LEDs in the lights respond very quickly. This tells the following traffic more quickly than usual that the brakes have been applied.

- Interior
The new 5-Series BMW is the first car in this class to have iDrive, and with it a radically new, innovative operating concept for convenience functions. Controller, gear lever or range selector lever and handbrake are integrated into the center console. The controller can be operated from both the driver's side and the passenger side.
The instrument panel of the new 5-Series BMW has been completely redesigned. The interior armrest is harmoniously integrated into the door panel and thanks to its width and ergonomic styling allows a comfortable and relaxed seating position.





- Front end
GRAV is an acronym of "gewichtsreduzierter Aluminiumvorderbau" and this lightweight aluminium front end enhances the lightweight design of the car. Almost the entire front end is made of aluminium. The transition to steel in the composite construction starts in the vicinity of the engine bulkhead. The reduced weight of the front end in particular contributes much to the ideal axle-load distribution of 50:50. by opting for an aluminium front end, the designers had to consider the electromagnetic compatibility (EMC) of the material. An aluminium body gives less effective screening against external electrical radiation. This means that separate screening is needed for wiring harnesses and control units. Moreover, an earth connection must be provided for riveted or glued aluminium components. For reasons of safety, individual components are therefore joined with welded seams in production. If a repair is needed, the function of the welded seams must be replaced by self-tapping screws.







Repairing an aluminium body requires new repair techniques in the workshop. As it is less pliable, it is not possible to stretch the material on the alignment bench and components that have been deformed in an accident must always be replaced. Repair are therefore likely to be more complex that they would be for steel bodies. Deformed aluminium components must be separated at predefined points and replaced with new parts. In order to ensure that the new parts would be held safely and securely, special aluminium insert elements were developed for the engine bracket, for example.





Insert element (top left) for repairing aluminium components or for sliding into the profiled section of the engine bracket (dark).


Electrics/electronics
- Vehicle circuit structure
The vehicle circuit structure for the data buses is largely based on the familiar vehicle circuit structure of the E65. In the E60 and the E61, the body-related CAN SYSTEM and the body-related CAN PERIPHERY combine to form what is known as the K-CAN system. The multi-audio system controller (M-ASK) and the Car Communication Computer (CCC) comprise multiple control units, which communicate via the MOST bus.

- Power supply
Power management monitors the vehicle's energy consumption. Power management also ensures optimized battery charging. To make sure the vehicle can be started, consumers may be switched off if the battery reaches a critical charge level. In the E60 and the E61, the functions of power management are discharged by the intelligent battery sensor (IBS) and the micro power module (MPM). The software for power management is in the following control units: Digital Engine Electronics (DEE), Digital Diesel Electronics (DDE), and in the intelligent battery sensor (= sensor with control electronics). Power management allows additional diagnosis of the battery and the vehicle electrical system.
[more in SI Technical (SBT) 61 07 03 029] Power Supply

- Car Access System
The Car Access System (CAS) in the E60 and the E61 is an evolution of the system in the E65. The CAS performs the following system functions:
- terminal control
- Convenient starting system with electronic immobilizer
- Radio remote control
- Centralized control of the central locking system
- Centralized control of the front and rear window lifters
- Centralized data storage and redundant data filing



[more in SI Technical (SBT) 61 03 03 019] Car Access System

- Central locking system
The Car Access System (CAS) monitors all the processes in the central locking system. The central locking system for the front doors is actuated by the driver's door module (TMFA) and the front-passenger door module (TMBF). The central locking of the rear doors, the tailgate and the fuel filler cap is actuated by the body basic module (KBM).
[more in SI Technical (SBT) 61 04 03 020] Central Locking System

- Wiper/washer system
The wiper/washer system can be operated when terminal R is switched ON. The clip that secures the wiper blades to the wiper arm is of a new design. The wiper/washer system no longer has spherical washer jets, but rather flat-spray jets (fluidic spray nozzles). The E60 and E61 have a rain-light sensor as standard. This means that the wipers can operate in automatic mode in most situations.
[more in SI Technical (SBT) 61 06 03 026] Wash/Wipe System E60/E61/E63/E64

- Exterior mirrors
The exterior mirrors are actuated by the driver's door module (TMFA) and by the front-passenger door module (TMBF). The door modules communicate with each other via the byteflight high-speed, optical data bus. The exterior mirrors are adjusted centrally at the switch block in the driver's door.
[more in SI Technical (SBT) 61 10 03 032] Exterior Mirrors

- Power windows
The power side windows are operated by a cable lift drive. The window lifters for the front doors are actuated by the driver's door module (TMFA) and the front-passenger door module (TMBF). The window lifters for the rear doors are actuated by the body basic module (KBM). The convenience functions of the window lifters (convenience opening/convenience closing) are controlled by the Car Access System (CAS).
[more in SI Technical (SBT) 61 05 03 025] Description and Operation

- Sliding/tilt sunroof
The electric sliding/tilt sunroof for the E60 is a glass sunroof. The electric sliding/tilt sunroof has its own control unit. The convenience functions of the sliding/tilt sunroof (convenience opening/convenience closing) are controlled by the Car Access System (CAS).
[more in SI Technical (SBT) 61 08 03 030] Sliding/Tilt Sunroof E60

- Panorama glass sunroof
Like the E83 and the E53, the E61 can be fitted with a panorama glass sunroof. The front glass panel can be fully opened or raised. The rear glass panel can be raised. This panorama glass sunroof has a wind deflector for reducing wind noise inside the passenger compartment: positioning of the wind deflector is speed-controlled.
[more in SI Technical (SBT) 61 12 03 055]

- Automatic opening and closing of the tailgate
The tailgate of the E61 opens either when a button in the handle is pressed, or automatically in response to a signal from the remote control unit. The tailgate is closed manually by pressing a button set in the tailgate. The tailgate also has an automatic soft-close function controlled by means of the remote control unit. It takes approximately 6 to 8 seconds to open or close the tailgate automatically.
The automatic soft-close function assists the hydraulic system, because the resistance of the rubber sealing strip has to be overcome as the tailgate closes. An eccentric pin engages the lock of the tailgate. An electric motor turns the eccentric pin downward. The force applied in this way overcomes the resistance of the rubber sealing strip, drawing the tailgate down so that it closes correctly.
The rear window opens slightly when the button underneath the rear wiper is pressed, or when the button on the remote control unit is actuated. The rear window is top-hinged and opens for loading and unloading. The rear window closes when it is pushed down into the closed position.