BMW 5 Series (E60)

The development programme for the E60 began in 1997, concluding in 2002. The lead designer was Boyke Boyer.[6] The final design, developed by Davide Arcangeli[7] under BMW Design Director Chris Bangle,[8][9] was approved in 2000 and German design patents filed on 16 April 2002.[10]

The sedan was launched on 5 July 2003 in Europe and in October 2003 in North America.[11][12][13] In late 2004, the Touring models were introduced.

• 
  Sedan (E60)
• 
  Long wheelbase sedan (E60)
• 
  Touring (E61)

The body of the E60 was made using aluminium for the front of the car, and steel for the passenger cabin and rear. Kerb weights are 1,445–1,725 kg (3,186–3,803 lb) for the sedan[14][15] and 1,675–1,830 kg (3,693–4,034 lb) for the wagon.[16][17] The weight distribution of the sedan models was 50:50.[18]

Interior (pre-facelift)

Head-up display

The iDrive infotainment system— first introduced in the E65 7 Series— was fitted to all E60 models. The standard iDrive system included a 6.5-inch LCD screen, a single-disc CD/MP3 player, Bluetooth for phone calls (available only on later-build 2004 models, and standard on all 2005 and newer models), basic voice control,[19] and vehicle settings. Optional features included an 8-inch LCD screen, GPS navigation, Sirius Satellite Radio (on North American-spec models), and DVD video playback. iPod and USB integration, HD Radio (on North American-spec models), an auxiliary audio input jack (standard on 2008 and newer models), full voice control, and a multi-disc CD/MP3/DVD changer (mounted in the glove compartment). On North American-spec models, a ten-speaker premium audio system with dual under-seat subwoofers and an amplifier was standard equipment, with a thirteen-speaker Harman Kardon "Logic 7" premium surround sound audio system available as an option on all models.

An emergency hotline feature (BMW Assist) was also available for the E60. The BMW Assist system could also use the phone network to notify the driver and their preferred BMW dealership when servicing was due. This feature was standard on all E60 models sold in the United States.

Other features available in the E60 initially included active cruise control, Bi-Xenon headlights, run-flat tyres, active anti-roll bars,[20] head-up display[21] and active steering.[9] Safety-related items include Dynamic Stability Control (DSC), adaptive headlights and night vision.

In 2009, the iDrive system was upgraded from the first-generation "CCC" interface to the newer "CIC" interface. The audio system control panel added six multifunction preset buttons that could be programmed to store favorite radio stations and frequently-dialed telephone numbers for the Bluetooth hands-free system. The iDrive controller in the center console was also redesigned, and now integrated shortcut keys for frequently-used functions.

Over the E60's lifespan, the following features were added: Active Cruise Control with Stop & Go,[22] keyless entry ("comfort access"), LED taillights,[23] Lane Departure Warning[19] and Brake Force Display.[24][25]

The E60 was the first 5 Series in 22 years where the centre console was not angled towards the driver,[19][26] however the E60's successor returned to angling the centre console towards the driver.[5]

In 2003 a 6-speed SMG-II gearbox was offered as an option on the 525i, 530i, 545i and 550i in some markets.[27]

Available transmissions are:

• 6-speed ZF S6-37 manual (2004–2010)
• 6-speed Getrag 217 -- GS6-17BG / GS6-17DG manual (2004–2010)
• 6-speed ZF S6-53 manual (2004–2010)
• 6-speed ZF 6HP19 automatic (2003–2007)
• 6-speed ZF 6HP26 automatic (2003–2007)
• 6-speed ZF 6HP28 automatic (2007–2010)
• 6-speed GS6S37BZ SMG-II (2003–2010)[28]
• 6-speed GS6S53BZ SMG-II (2003–2010)[28]
• 7-speed GS7S47BG SMG III (M5 model)[29]

M5 sedan (E60)

The M5 model of the E60 generation was introduced in 2005 and produced in sedan and wagon body styles. The E60 M5 is powered by the BMW S85 V10 engine, which produces 373 kW (500 hp) at 7,750 rpm, 520 N⋅m (384 lb⋅ft) at 6,100 rpm and has a redline of 8,250 rpm.[30][31] The 0–100 km/h (0–62 mph) acceleration time is 4.7 seconds.[32]

The majority of M5s were sold with a 7-speed automated manual transmission ("SMG III"),[33][34] however a 6-speed manual was also available in some markets.

Total production of the M5 was 20,548 units, consisting of 19,523 sedans and 1,025 wagons.[35]

section view- front

section view- side

Initially the 5 Series received a three-star rating for adult occupants.[43] However changes were made to the steering column, footrest, door trims, door latch, airbags and electronic software and the car was retested achieving its four-star rating. BMW claims the modifications improved the car's Euro NCAP score, not the vehicle's safety; consequently BMW chose not to recall the earlier-built cars.[44]

The American Insurance Institute for Highway Safety (IIHS) gives the 5 Series a "Good" overall rating in frontal collisions but a "Marginal" overall rating for side impact collisions.[45][46] The IIHS reported their side impact test would likely cause driver related rib fractures and/or internal organ injuries. The IIHS tests were conducted on models built after May 2007; these models had modifications to improve side impact safety.

Euro NCAP scores (2004 sedan)[47]

Adult Occupant:
Child Occupant:
Pedestrian:

NHTSA scores (2008 sedan)[48]

Frontal Driver:
Frontal Passenger:
Side Driver:
Side Rear Passenger:
Rollover:

The 'Life Cycle impulse' (LCI) models were introduced in March 2007 (for the 2008 model year). Styling changes were relatively subtle, and included revised headlights, tail lights and front bumper.[23] The interior was significantly revised. The iDrive system was upgraded with programmable "favourite" shortcut buttons (for 2009 models), a revised menu system, preset buttons for the audio system and the switch from DVD to hard disk based storage (for 2010 models).[49]

Mechanically, the 5 Series gained the new engines and transmissions from the E70 X5. On automatic transmission models, a shift by wire shifter replaced the mechanical version and shift paddles were available for the first time on a 5 Series model besides the M5.[23]

The active cruise control was upgraded to bring the vehicle to a complete stop and accelerate from stationary (called "Stop & Go"). Other changes include adaptive headlights, LED rear lights, Lane Departure Warning,[50] night vision[51] and Brake Force Display. The E60 LCI was the first BMW to feature regenerative braking.[22]

• Facelift exterior changes
• 
  Pre-facelift front
• 
  Pre-facelift rear

• 
  Post-facelift front
• 
  Post-facelift rear

Production of the E60/E61 occurred at the BMW Group Plant Dingolfing in Germany[52] and at the BMW Brilliance plant in China.[53]

Complete knock-down assembly of German-produced kits took place in Thailand,[54] Egypt,[55] Russia[56] and Malaysia.[57]