2023年宝马5系E60手册技术最全面精品资料mfpbrke60karosseriegesamtf_en.pdf

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1、(%RGr&RPSOHWHYHKLFOH3DUWLFLSDQW0DQXDOBMW ServiceNOTEThe informationcontainedin this trainingcoursemanualis intendedsolelyforparticipants of the BMW Service Training course.Refer to the relevant Technical Service information for any changes/supplements to the Technical Data.2002 BMW AGMnchen,Germany.

2、Reprints of this manual or its partsrequire the written approval of BMW AG,MnchenVS-42 MFP-HGK-BRK-E60_0220ContentsPageCHAP 1E60 Body-Complete Vehicle1Introduction1Front body components5-Bonnet5-Front side panels5-Engine compartment6-Headlight unit7-Front fog lights8-Front bumper9-Front end10-Windsc

3、reen11-Windscreen washer system12-Door mirrors13-Roof mouldings,sill trim panels14-Front doors15-Location of control units in passenger compartment17-Instrument panel22-Centre console24-Front seats26-Rear seats30-Airbags32Rear body components32-Rear side panels32-Boot lid32-Rear window34-Boot35-Loca

4、tion of control units in boot36-Rear light clusters39-Rear bumper41Slide/tilt sunroof42Vehicle underbody44E60 Body-Complete vehicle-1-E60 Body-Complete VehicleIntroductionIn the first half of 2003,production of the E60 will be phasedin at theDingolfing plant,replacing the E39.The E60 represents a co

5、ntinuation of the 5 Series tradition.(E12-E28-E34-E39-E60)Fig.1:Front view of E60E60 modelsFrom 09/03,the 525i and 545i will be introduced.520i530i530dKT-11012E60 Body-Complete vehicle-2-Fig.2:Side view of E60DimensionsFig.3:External dimensions,height/widthin mmE60E39DifferenceLength48414775+66Width

6、18461800+46Height14691435+34KT-11013KT-11142E60 Body-Complete vehicle-3-Fig.4:External dimensions,lengthWeightsAlthough the E60 is noticeably longer,wider and higher than the E39,its unladen weight is approximately36 kg lighter.E60(530i)E39(530i)DifferenceUnladen weight(kg)15701606-36Payload(kg)5605

7、40+20Boot capacity(l)520460+60KT-11144E60 Body-Complete vehicle-4-Fig.5:Rear view of E60DesignThe individual character of the E60 has been consciously emphasized.As a result,the new5 Seriesdoesnot simplyresemblea small7 Seriesor a large 3 Series.Fig.6:Side view of E60KT-11016KT-11014E60 Body-Complet

8、e vehicle-5-Front body components-BonnetThe bonnet is made of aluminium.It can be set to opento a servicingposition.This requiresa specialtool.So that the clearancegapsfrom the side panelsand the bumpercan beadjusted,there are slots where the hinges and the bonnet lock aremounted.Fig.7:E60 External

9、dimensions,boot and bonnet overhead clearance-Front side panelsThe front side panels also are made of aluminium.They are bolted to the bodyshell and therefore easily replaceable ifdamaged.The side-panel fixing points also have slots to enable adjustment ofclearance gaps and alignment.KT-9517E60 Body

10、-Complete vehicle-6-Engine compartmentThe following important control units are located in the enginecompartment:In the electronics box at the front left-Digital engine management(DME/DDE)-Electronic transmission module(EGS,6-cylinder only)-Sequential manual gearbox(SMG),if fitted-Integrated power s

11、upply module(IVM,8-cylinder only)-VALVETRONIC control unit(VVT,8-cylinder only)The DSC(dynamic stability control)control unit is also fitted in theengine compartment.The wash/wipe module is located on the windscreen wiper linkage.Attached to the front cross-panel behind the bumper trim panel is theA

12、ctive Cruise Control(ACC)control unit.The vehicle identification number is stamped into the front rightsuspension strut mounting.The suspension strut mounting has slots for attaching the suspensionstrut.The camber angle is adjusted by knocking out the suspensionstrut pin and adjusting the suspension

13、 strut in the slots.Access to the microfilters for the heating/air-conditioning systemthroughthe enginecompartmentis also very straightforward.The filtersare very easy to replace.An entirely new feature of the front body section is the lightweightaluminium front end structure.E60 Body-Complete vehic

14、le-7-Headlight unitHalogen headlights are fitted as standard.Fig.8:Headlight unit functionsBi-xenonheadlightsare availableas an option.The bi-xenonheadlightsare supplied as part of an option package in combination with theadaptive headlights(AHL)feature.The adaptive headlights have aswivelling dippe

15、d beam which follows the movement of the steeringwheel,thus illuminating bends in the road better than conventionalheadlights.IndexExplanationIndexExplanation1Design feature(with bi-xenonheadlightscontainsLEDs for sidemarker light)4Fibre-optic ring lights for sidelights2Direction indicators5Reflecto

16、r for main beam headlight3Reflector for dipped headlightsKT-11137E60 Body-Complete vehicle-8-The bulbsin the halogenheadlightscan be replacedwith the headlightunit in situ.Replacement of the bulbs in the bi-xenon headlightsrequires removal of the headlight unit.There are two easily accessible adjust

17、ing screws(for vertical andhorizontal adjustment)for adjusting the alignment of the headlamps.There are apertures in the aluminium front cross-panel to allow accessto the adjusting screws.-Front fog lightsThe front fog lampsare fixed insidethe bumpertrim panelby 2 boltsineach case.There is a third s

18、crew for adjusting the front fog lamps.Theadjusting screw is accessible from the outside without having toremove any other components.The side grille has to be unclipped inorder to gain access to the adjusting screw.E60 Body-Complete vehicle-9-Front bumperFig.9:Front bumperIndexExplanation1Bumper cr

19、oss-member with deformation elements2Impact absorber3Brake air cowl4Bonnet seal5Bumper trim panel side mounting brackets6Side bumper inserts7Bumper trim panel8Side air grilles9Blanking plates for the brake air cowls10Vibration damper strip11Centre air grilleKT-10798E60 Body-Complete vehicle-10-Minor

20、impactsat speedsup to 4 km/hare absorbedby the bumpertrimpanel and the foam impact absorbers.These components return totheir original shapes of their own accord.At speeds up to 15km/h non-elastic deformation elements absorb theimpact forces.US versionInstead of deformation elements,the US versions h

21、ave impactdampers.The bumper trim panel and the foam impact absorbers protect thevehicle structure from impacts at speeds up to 8km/h.These compo-nents return to their original shapes of their own accord.Only at impact speeds upwards of 15km/h does the engine subframestructure suffer damage.Bumper c

22、ross-memberThe bumper cross-member is made of aluminium and can be replacedseparately.In order to prevent damage to the aluminium bumper cross-member,the specifiedtighteningtorquesfor the fixing pointsshouldbe carefullyobserved.-Front endOn the E60,the entire front end can be removed.The front end c

23、onsists of the front cross-panel,the deformationelements and the bumper cross-member.E60 Body-Complete vehicle-11-WindscreenThe windscreen is made of 4.5 mm green-tinted laminated glass.The following options are available:-Infra-red climate-enhancing windscreen-Infra-red theft-inhibiting laminated s

24、afety glass windscreen-Windscreen with green-tinted sun visor stripOn the E60,precise positioning of the windscreen when fitting isextremely important.It is essential that the repair instructions arefollowed precisely when replacing the windscreen not only because ofwind-noiseconsiderationsbut alsob

25、ecauseof the requirementsof thehead-up display option.E60 Body-Complete vehicle-12-Windscreen washer systemFig.10:Windscreen wiper systemOn the E60,the windscreen washer system is designed in such a waythat the washer jets do not have to be adjusted and the wiper bladesare easily replaceable.The win

26、dscreen washer fluid reservoir has a capacity of 3litres.If the headlamp washer system is also fitted,the washer fluid reservoirhas a capacity of 5litres.The angle of inclination of the wiper blade to the windscreen isadjustable on both sides.To do so,the cover must be unclipped so asto access the a

27、djusting screw underneath.The wiper system is supplied in the reversing position so that the leftfixing bracket is accessible for attachment to the vehicle.IndexExplanationIndexExplanation1Wiper blade6Deep-drawn tube2Wiper arm7Jointed rod3Multi-rod linkage cover plate8Operating arm4Electric motor wi

28、th control unit9Right fixing bracket5Left fixing bracket10Control armKT-10832E60 Body-Complete vehicle-13-For that reason,the flick-wipe setting should be selected before fittingthe wiper arms so that the motor moves to the parked position.Onlythen should the wiper arms be fitted.If the wiper arms s

29、hould have to be removed in order to replace thewindscreenor for any otherrepairwork,the fixingsbetweenthe controlarm/operatingarm and the right fixing bracketshouldbe disconnected.In that waythe wiperbladeanglewill not haveto be resetafterrefitting.-Door mirrorsBoth door mirrors are electrically ad

30、justable and heated.The following options are available:-Memory function-Electrochromic mirrors with folding function-Integrated exterior illumination lightThe mirror body,mirror surround and mirror glass are all separatelyreplaceable.The mirror body and the mirror glass are held together by clips.T

31、he mirror surround is a snap fit.In orderto completelyremovethe doormirror,the doortrim panelmustbe removed in order to gain access to the connector to the doormodule.E60 Body-Complete vehicle-14-Roof mouldings,sill trim panelsOnly the roof moulding strips and the sill trim panels are used on thismo

32、del.The roof moulding strips are easy to fit,being attached to the roofchannel by 7clips.The sill trim panels are made of a thermoplastic material finished inbody colour.Fig.1 1:Left-hand sill trim panelThe sill trim panelsare pressedinto the sills frombelowusing8 spacerclips.They are alsoattachedat

33、 the rear from belowby a singleTorx boltin each case as well as having a further 8clips that clip into the sillsfrom the side.There is a retaining bracket bolted onto the side panels on each sideinto which the sill trim panels locate rearwards.At the front,the sill trim panelsare fixed by a singlesc

34、rewto the wheel-arch liner in eachcase,whileat the rear they are attachedto the wheelarch liners together with the air fins by 2screws.KT-10958E60 Body-Complete vehicle-15-Front doorsThe design of the doors is the same as that used on the E65.The doors are composed of a door outer panel,a door inner

35、 panel,adoor outer skin reinforcing bar,a lock plate and a diagonally mountedside-impact bar.Fig.12:Front door structureThe exterior door handle is a three-piece assembly.It consists of amounting plate fitted from the inside,a handle recess plate fitted fromthe outside and the handle fitted and scre

36、wed onto the recess platefromthe outside.The mountingplatesealsthe recessplateagainstthedoor outer panel.The handle braces itself against the mounting plate.A special tool is used to remove the exterior door handle.IndexExplanationIndexExplanation1Diagonally mounted side-impact bar3Lock2Exterior doo

37、r handle mounting platewith door handle and recess plateKT-10954E60 Body-Complete vehicle-16-The door trim panel is fixed to the top of the inner door panel by6 catches and is clipped around the outer edges.Fig.13:Drivers door trim panelUnderneath the airbag symbol there is a fixing screw for the do

38、or trimpanel.The door control module is located behind the door trim panel.The airbag module is fixed to the door trim panel.A plastic sound insulation panel acts as a moisture seal as well asreducing noise.It is fixed between the door trim panel and the innerdoor panel.The window regulator is a twi

39、n-cable,outside-mounted,cable-operated mechanism.The doorlock is a so-calledL-type lock that has beenusedon the basicversion of the E65 since 01/09/02.To remove the door lock,the window glass and the window regulatorhave to be removed.KT-10971E60 Body-Complete vehicle-17-Location of control units in

40、 passenger compartmentIn the instrument panel area:Fig.14:Control units in the instrument panel areaIndexExplanationIndexExplanation1Door module,drivers side(TMFA)9Tyre Pressure Control(RDC)2Steering column switch cluster(SZL)10Body basic module(KBM)3Instrument cluster(KOMBI)11Safety and Gateway Mod

41、ule(SGM)4Multi-Audio System Controller(M-ASK)12Door module,passenger side(TMBF)5Integrated automatic heating/airconditioning(IHKA)13Active Roll Stabilization(ARS)6Central Information Display(CID)14Controller(CON)7Centre console switch centre(SZM)15Car Access System(CAS)8Adaptive Headlights(AHL)16Lig

42、ht module(LM)KT-11204E60 Body-Complete vehicle-18-Fig.15:Control units in the central instrument panel areaIndexExplanationIndexExplanation1Central Information Display(CID)3Multi-Audio System Controller(M-ASK)2Integratedautomaticheating/airconditioning(IHKA)4Centre console switch centre(SZM)KT-11205

43、E60 Body-Complete vehicle-19-If active steering is fitted,the active steering control unit(AFS)islocated in the right front footwell.The associated yaw-rate and lateralacceleration sensor(DSC sensor)is bolted to the floor panel under-neath the left front seat.The yaw-rate and lateral acceleration se

44、nsor for the Dynamic StabilityControl(DSC)system is fixed to the floor panel underneath the rightfront seat.If the DynamicDrive(ARS)option is fitted,the associated lateral accel-erationsensoris alsofixed to the floor panelunderneaththe right frontseat.Fig.16:Location of active steering control unit

45、and DSC sensorsIndexExplanationIndexExplanation1DSC sensor for active steering3Active steering control unit2DSC sensor for DSCKT-11316E60 Body-Complete vehicle-20-Fig.17:Control units in the left passenger compartment areaIndexExplanationIndexExplanation1B-pillar satellite,left(SBSL)4Seat module,pas

46、senger side(SMBF)2Phone module5Seat module,drivers side(SMFA)3Controller6Vehicle centre satellite(SFZ)KT-11207E60 Body-Complete vehicle-21-Fig.18:Control units in the roof areaIndexExplanationIndexExplanation1Antenna amplifier3Slide/tilt sunroof module(SHD)2Ultrasonic passenger-compartment sensor(US

47、IS)4Rain/light sensor(RLS)KT-11209E60 Body-Complete vehicle-22-Instrument panelThe instrument panel consists of a mounting bracket made of glass-fibre reinforced polyurethane plastic with a foam-backed sprayedpolyurethane outer skin as the external surface.The surface texturecreates the impression o

48、f leather.The instrument panel mounting bracket is attached to the bulkheadcross-member and the tubular supporting frame and the transmission-tunnel bracket at 10 points.Fig.19:Instrument panel mounting bracket fixing pointsIndexExplanation1Fixing point to bulkhead cross-member2Fixing point to tubul

49、ar supporting frame3Fixing point to transmission-tunnel bracketKT-11195E60 Body-Complete vehicle-23-The grilles are screwed to the decorative strip on the inside.The instrument panel fits onto 4mounting plates on the bulkheadcross-member.Behind the clip-on instrument panel decorative strips and the

50、slot-incarpet trims on the transmission tunnel there are screw fixings asfollows:-1 fixing underneath the decorative strip on the left ventilation grille-2 fixingsunderneaththe large decorativestrip;one next to eachof thecentre ventilation grilles-1 fixings at bottom right under the edge of the glov