Complete Vehicle

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Complete vehicle
E63, E64





Highlights in brief
The BMW 6-Series represents perfection in the synthesis of sports car and luxury saloon:
an extremely low coupe (E63) and a convertible (E64). 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, steel and plastic actually increases space and comfort.
The systems described in brief in this document are as follows:
- Body
- Design
- Interior
- Front end
- Front side panel
- rear lid
- reinforcement of the body

- Electrics/electronics
- Vehicle circuit structure
- Power supply
- Car access system
- Central locking system
- Wipe/wash system
- Exterior mirrors
- Power windows
- Electric glass sunroof with tilt function
- Fully automatic soft-top (hood)
- 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)

- 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 E63 and E64 have been redesigned. Lighted optical-fiber bars above the headlights and the familiar parking-light rings provide a new, unmistakable design.





The rear lights consist of 2 parts. The top part is integrated into the side wall and the bottom part is integrated into the bumper.
The top part consists of:
- turn signal lights
- two-stage brake lights
- tail lights
The tail light consists of 6 fiber-optic bars with LED light sources.
The E63 and E64 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.
The bottom part consists of:
- rear foglight (not on US version)
- Reversing light
- rear reflector





Rear lights, E63, E64

- Interior
Like the 5-series, the new BMW 6-series is equipped with iDrive. The controller, gear lever/selector lever and the parking brake are located in the centre console. The controller can be operated from both the driver's side and from the passenger side.
The dashboard is basically the same as that on the 5-series. Instead of the fuel-consumption gauge in the revolution counter, the E63 and E64 have a gauge that shows engine-oil temperature. 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 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).

- Front side panel
The front side panels are made of plastic (thermoset plastic).

- Boot lid
The boot lid is made of a fiberglass-based composite material.

- Reinforcement of the body
The body of the E64 requires more high-strength steel reinforcing components than the E63. The body parts reinforced in this way are:
- A-pillars
- Upper scuttle
- Side ribbing, inside
- Side sills
The doors are reinforced by two extruded aluminium sections forming a Vee. The rear heel-board, the cross-members underneath the seats, and the rear bulkhead are also reinforced.
Extra longitudinal members underneath the seats are a new feature of the E64. In the event of a side crash, these members dissipate the forces through the seats and into the floorpan.
The advantages of the reinforced body are: high rigidity and excellent crash resistance.

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 E63 and the E64, 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 E63 and the E64, 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), Digitale 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]

- Car Access System
The Car Access System (CAS) in the E63 and the E64 is an evolution of the system in the E65. The CAS performs the following system functions:
- terminal control
- Convenient starting system with electronic immobiliser
- Radio remote control
- Centralised control of the central locking system
- Centralised control of the front window lifters (E63)
Centralised control of the front and rear window lifters (E64)
- Centralised 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 doors is actuated by the driver's door module (TMFA) and the front-passenger door module (TMBF). The central locking of the boot lid 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 E63 and E64 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).
In the E64 the rear window lifters 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).
In addition to the front and rear side windows, the vertical, heated rear window of the E64 is also electrically lowerable.
[more in SI Technical (SBT) 61 05 03 025] Description and Operation

- Electric glass sunroof with tilt function
The glass sunroof (E63 only) is made of 4 mm toughened glass and can be tilted. When the glass sunroof is tilted, two specially developed bellows-type adapters (outer and inner) minimise the noise of the slipstream. The floating headliner has two sections and can be stacked. The floating headliner consists of bonded aluminium sheets enclosing a cushion of air (sandwich structure). This prevents the interior of the car from heating up when the sun is shining.
- Fully automatic soft-top (hood)
The electro-hydraulic soft top of the E64 can be opened and closed automatically. It takes approximately 25 seconds to open or close the soft top. The top is moved by hydraulic cylinders. An electric motor engages and disengages the latching mechanism on the scuttle. When the soft top opens it retracts into the soft-top compartment. The top of the soft-top compartment then closes automatically. The remote control unit can be used to open the automatic soft-top with the "convenience opening" function.
The soft top tails off into two fins at the rear. This design means that the roof can accommodate the vertical, retractable rear window.
[more in SI Technical (SBT) 54 01 04 077]





Vertical, retractable rear window

- Anti-theft alarm system
The anti-theft alarm system (DWA) detects and reports attempts at intrusion and tampering with the vehicle. The vehicle interior is monitored by microwave sensors.
If an attempt is made to gain access to the vehicle interior, an acoustic alarm is triggered from the emergency power siren and a visual alarm via the lighting system (hazard warning lights). A tilt alarm sensor is tripped if the vehicle is raised or taken in tow. The tilt alarm sensor responds by triggering the anti-theft alarm.
[more in SI Technical (SBT) 65 04 03 061] Anti-Theft Alarm System

- Passive safety system
At this time, BMW is the only carmaker to offer the "Advanced Safety Electronics" (ASE) passive safety system. ASE is based on the byteflight high-speed, optical data bus. Individual sensors permit optimum control of the pyrotechnical components of the restraint system (e.g. airbags, belt tensioners and active head restraints). The safety and gateway module (SGM) has the role of superordinate control unit and intelligent star coupler. Moreover, the SGM also make available an energy reserve for the entire safety system in the event of the power failing in a crash. If the accident severity is above a certain threshold the electric fuel pump is switched off. The safety battery terminal (SBK) separates the starter motor and the alternator from the battery's positive post. The onboard power supply is connected to the battery. This means that all emergency functions are retained in the event of a crash.
The E64 has a rollover protection system. Rollover sensors detect an incipient rollover situation. The rollover protection actuators are tripped. The actuators release the spring-loaded rollover bars. The rollover bars deploy within 300 ms.

- iDrive, central information display and controller
The iDrive system from the E60 and E61 has been imported into the E63 and E64. iDrive the leading man-machine interface in this sector. iDrive has an excellent, self-explanatory operating logic. The menu structure has been further developed and simplified. The start menu is now subdivided into four colour-coded sections, "Communication", "Navigation", "Entertainment" and "Air-conditioning".
The Central Information Display (CID) is available in 2 different sizes (6.5 and 8.8 inch), depending on equipment specification.
iDrive has been given an additional menu button. The single-piece menu button from the multi-audio system controller
(M-ASK) allows a quick return to the start menu. On the Car Communication Computer (CCC), there is an additional second button for the voice recognition system.
[more in SI Technical (SBT) 62 01 03 027] Description and Operation

- Head-up display
The Head-Up Display (HUD) projects a "virtual" image in front of the windscreen. The image is projected approximately 2.20 m ahead of the windscreen. The image is visible only from the driver's side. This driver-relevant information contained in this "virtual" image depends on the vehicle equipment, and can include, for example:
- Car road speed
- Cruise control (FRG) or Active Cruise Control (ACC)

- Navigation instructions
- Check-Control messages
[more in SI Technical (SBT) 62 03 03 043] Description and Operation

- Instrument cluster
The round instruments of the instrument cluster in the E63 and the E64 have 2 moving-segment indicators. The moving-segment indicator on the left is around the speedometer. The left moving-segment indicator shows the speed setting (= selected speed in mph for the cruise-control system). The moving-segment indicator on the right is around the revolution counter. The right moving-segment indicator shows the engine-overspeed warning field (engine speed limits vary, depending on engine temperature). Between the two round instruments there are an LCD display and a number of indicator and warning lights.
The brightness of the liquid-crystal display adjusts to suit ambient brightness. At temperatures under 10 ° Celsius the liquid-crystal display is heated, in order to ensure good legibility right from the beginning.
Engine-oil temperature, not fuel consumption, is shown in the right round instrument (revolution counter).
[more in SI Technical (SBT) 62 02 03 028] Description and Operation

- Adaptive headlights
Adaptive Head Light (AHL), option code 524, is available only in combination with option code 522 "Xenon lights".
As the car corners, AHL pivots the low-beam headlights and the high-beam headlight slightly toward the inside of the corner (in other words, to the right if the car is cornering to the right). The curve is then illuminated better and visibility is improved. If the vehicle drifts, skids or loses sideways grip, the adaptive headlights function is deactivated. The headlights are then returned to the straight-ahead position.
[more in SI Technical (SBT) 63 02 03 007] Adaptive Headlights

- Integrated automatic heating and air-conditioning system
The E63 and the E64 are equipped with the High version of the integrated automatic heater and air-conditioning system (IHKA) as standard.
[more in SI Technical (SBT) 64 01 03 006] Integrated Heating Control and Air-Conditioning System
BMW patented "convertible mode" debuts in the E64. When the soft top is opened, the IHKA is controlled by a customised automatic program. The following custom automatic programs can be selected in the "Settings" menu:
- Gentle
- Medium
- Intensive
By contrast with the saloon, when the soft top is open heated or cooled air flows out to the upper-body zone and to the head zone. External influences and the associated fluctuations in temperature are more perceptible in an open-topped car than in a closed passenger compartment. These external influences (day/night transitions, sunlight, clouds, shade) are registered by the solar sensor. The IHKA control unit compensates for these influences. The blower of the E64 is regulated as a function of roadspeed. The volume of air increases as the car speeds up. The car's occupants experience no perceptible change in comfort despite the change in boundary conditions. Optimum comfort is achieved in combination with the draft deflector or with the rear window closed.

- Park Distance Control
The Park Distance Control (PDC) system from the E65 has been adapted for the E63 and the E64.
New for the PDC in the E63 and E64: The signal from the PDC button is transferred through the K-CAN to the PDC control unit. The signal from the reverse-light switch (reverse gear engaged) on vehicles with manual transmission is transferred from the light module to the PDC control unit via the K-CAN. As in the E65, the visual alarm is also shown in the Central Information Display (CID).
[more in SI Technical (SBT) 66 01 03 051] Description and Operation

- Information and communication systems
The Multi audio-system controller (M-ASK) is installed as standard in the E63 and E64. The following systems are controlled by the M-ASK:
- Audio functions
- Central Information Display (CID, 6.5 inch)
- Navigation system (option code 606)
[more in SI Technical (SBT) 84 01 03 004] Multi-Audio System Controller
In the "High" version, this control function is assumed by the Car Communication Computer (CCC). The following systems are controlled by the CCC:
- Audio functions
- Central Information Display (CID, High version with 8.8" display)
- Voice recognition system
- DVD navigation system Professional (option code 609)
[more in SI Technical (SBT) 84 06 03 053] Car Communication Computer
The M-ASK and the CCC are programmed using the MOST port.
The navigation system receives its map data from a navigation DVD.

- Condition Based Service
Condition Based Service (CBS), as the name suggests, is a means of ensuring that the car is serviced as and when necessary. CBS has been in use by BMW Service since the launch of the E65.
CBS is a landmark in the increasingly close communication and networking between vehicles and Service. The vehicle's specific service needs are registered manually or by TeleService. TeleService can issue an automatic service call, notifying the home dealership when service is due. The instrument cluster indicates whether a service is due.
When terminal 15 is switched ON, the "Next Service" indicator appears in the LCD display (remaining visible for 6 seconds). More information on CBS can be called up at the same time on the central information display (CID). There are currently nine defined service scopes:
- Engine oil
- Micro filter
- Brakes front
- Brakes rear
- Brake fluid
- Vehicle check
- Spark plugs (DME only)
- Roadworthiness test
- Exhaust emissions test

The service interval can be reset by means of the reset button in the instrument cluster (press and hold down for longer than 5 seconds). The scheduled times for the roadworthiness test and the exhaust-emissions test can be entered through the Controller or the Central Information Display.

Suspension






- Aluminium suspension
Intelligent lightweight construction was a definitive aspect of the design brief for the E63 and E64. The innovative aluminium chassis and running gear factor into weight reduction, as does the lightweight aluminium front end (GRAV). The control arms and transverse links are made of aluminium and ensure high-precision tracking of the wheels. The highly innovative design principle with the special layout of the leading links and control arms ensures high-precision steering. The low axle loads, especially in the area of the front axle, also provide for a high degree of agility and for the familiar BMW handling characteristics. Aluminium wheels and generously dimensioned aluminium brake calipers round off the intelligent lightweight construction concept.
- Active front steering
Active Front Steering (AFS) comes complete with Servotronic in the E63 and E64, as in the E60. AFS varies the ratio of the steering gear from direct to indirect and vice versa as a function of the car's speed.
The benefits of Active Front Steering are:
- Direct steering with light steering effort at low speeds
- Indirect steering at high speeds with positive directional stability
At low speeds, Active Front Steering reduces the number of steering wheel tuns required to move the wheels from lock to lock: instead of three full turns as in the past, less than two complete turns suffice to move the wheels from full lock to full lock. Less effort is needed to turn the steering wheel when turning in urban traffic or manoeuvring in tight parking spots.
Active Front Steering damps rotary movement of the car about its vertical axis. AFS intervenes electronically and imperceptibly at all speeds. This means that Dynamic Stability Control (DSC) intervenes less frequently and its action is less noticeable.
Unlike steer-by-wire systems, Active Front Steering has a mechanical link between the steering wheel and the front wheels. The authentic "feel" of the steering is sustained even if the AFS system fails.
[more in SI Technical (SBT) 32 01 03 001] Active Steering

- Dynamic Stability Control
Dynamic Stability Control (DSC 8) is standard in the E63 and the E64. DSC 8 was evolved from the DSC system installed in the E65.
The key new features are:
- Very compact DSC unit, approximately 25 % smaller and some 30 % lighter
- No electric pre-pressurising pump
- DSC unit connected to the chassis CAN (F-CAN) and the powertrain CAN (PT-CAN)
[more in SI Technical (SBT) 34 02 03 042] Dynamic Stability Control DSC 8

- Dynamic drive
The E63 and E64 in the 6-Series from BMW also have Dynamic Drive (ARS, Active Roll Stabilisation). The hydraulic Dynamic Drive system is a weight- and energy-optimized active control system for the chassis and running gear. Dynamic Drive prevents the car from yawing (= pivoting about the longitudinal axis when cornering). In this way, Dynamic Drive increases directional stability. It is based on vertically split stabilisers on both axles. Each half of the anti-roll bars has a hydraulic pivot motor, which reacts within milliseconds to adjust the running gear to changing driving situations.

- Runflat indicator
The runflat indicator (RPA) also belongs to the standard equipment on the new BMW 6-series. The runflat indicator is integrated in the DSC control unit. By comparing the speed signals for all four wheels, the system detects differences in rolling circumference at the individual wheels. A flat tire is indicated when a discrepancy is detected.
[more in SI Technical (SBT) 36 01 04 078]
11 00 ... Mounting Engine on Assembly Stand
- Tires with emergency-running characteristics (run-flat tires)
The E63 and E64 are fitted with tires with emergency-running characteristics as standard.
These tires have reinforced sidewalls. This makes the tires self-supporting: even when deflated, the tire retains its strength and does not go flat. In the event of a puncture, therefore, the car can be driven to the next workshop, as follows: Maximum range of 150 kilometres at medium load and a speed of max. 80 km/h.

Drive train
- Engines
The E63 and the E64 both have the familiar 8-cylinder engine (N62B44).

- Transmission
The transmissions available for the E63 and E64 are as follows:
- 6-speed manual transmission
- 6-speed automatic transmission

- Sequential manual transmission
A sequential manual gearbox (SMG) is available for the E63 and the E64. The gears are shifted sequentially. The driver shifts gear by moving the gear lever in the centre console or by means of the two paddles on the steering wheel.
[more in SI Technical (SBT) 23 03 03 044] Sequential Manual Gearbox E60, E61, E63, E64

Subject to change.