All New BMW 5 Series - In Depth

Press Release

All New BMW 5 Series - In Depth

Powertrain:
The Power and Efficiency of Six Cylinders and Six Gears Highlights
Straight-six spark ignition power units with bi-VANOS
Second-generation straight-six diesel power unit
Manual and automatic six-speed transmissions
Powerful and refined, agile and economical ??????????????????????????????????????? these are the four attributes which describe the new 5 Series?????????????????????????????????????? powertrain most appropriately. Features defined not only through the high technical standard of the individual components, but also by the supreme harmony of the entire powertrain. This starts with the outstanding six-cylinder spark ignition bi-VANOS power units and extends all the way to the second-generation common rail diesel all acknowledged as leaders the world over through their superior refinement, performance, efficiency and emission management based on that outstanding BMW know-how. Electronically masterminded, all of these engines interact perfectly with six-speed transmissions enabling the driver to transform the power of the engine into actual drive power on the road with maximum efficiency, whether with a manual gearbox or with automatic transmission. This supreme harmony is also ensured by features such as the light- alloy propeller shaft, the differential matched individually to each engine, and the wheel drive shafts reduced for minimum weight. Six-cylinder spark ignition power units Sharing a common foundation, the spark ignition power units in the 520i and 530i are acknowledged worldwide as benchmarks in six-cylinder engine technology: The BMW straight-six is the epitome for dynamic performance, superior refinement, high specific output on very low emissions, and outstanding all-round economy. Benefitting from the exceptional smoothness and refinement of these straight-six engines combined with bi-VANOS technology, the driver of the 5 Series enjoys turbine-like power and performance throughout a broad range of engine speed. And at the same time the customer benefits from superior fuel economy combined with low emissions. This leadership is attributable to a whole range of convincing achievements in technology: Four-valve technology for superior cylinder management, a resonance intake manifold, adaptive knock control, and individual coils have been standard features on BMW six-cylinder power units for a long time. Added to this there is bi-VANOS, the world??????????????????????????????????????s first infinite camshaft adjustment serving to move the opening and closing points of the intake and outlet camshafts smoothly from ???????????????????????????????????retard???????????????????????????????? to ???????????????????????????????????advance???????????????????????????????? and vice versa. This fully automatic control function takes effect between the timing chain and the camshafts, the change in the relative position of the crankshaft versus the respective camshaft and, accordingly, the change in valve opening times serving in particular to control the flow of residual gas (internal exhaust gas recirculation) as a function of the operating point with the following objectives:

• To ensure an optimum cylinder charge and supreme power under full load as well as optimum smoothness and refinement when idling by keeping residual gas to a minimum.
• To improve fuel efficiency and reduce emissions by increasing the share of residual gas under part load.

Special swirl ducts for each cylinder significantly improve the combustion process to an even higher standard, intake air flowing in through these ducts to the optimum point right in front of the intake valves. The purpose of these ducts is to increase the velocity of the fuel/air mixture flowing into the cylinders at low engine speeds and loads. This provides better fuel/air mixture preparation, allowing a retarded ignition angle and, in turn, reducing emissions and fuel consumption to an even lower level. Combined with the benefits of infinite, fully automatic bi-VANOS, this offers far more possibilities of optimising the fuel/air mixture according to current demands than with conventional fuel supply systems. Benefitting from these superior technologies, these straight-six power units are the first BMW engines to fulfil the world??????????????????????????????????????s strictest ULEV II (Ultra Low Emission Vehicle) emission standard in the USA. And it therefore almost goes without saying that they already comply today with the EU4 standard in Europe not coming into force until 2005, offering customers in Germany a tax relief of up to Euro 300. Sweden, incidentally, also pays a tax benefit for the premature fulfilment of future emission standards, meaning that owners of the 5 Series in Sweden also enjoy such a financial advantage. The combination of bi-VANOS, the resonance intake system and the two-chamber exhaust system serves furthermore to boost maximum torque to a very high level of 100 Nm/ltr between 3,500 and 4,500 rpm, with maximum output per litre of 57 kW or 78 bhp. And a minimum of 90 percent of the engine??????????????????????????????????????s maximum torque is consistently available throughout the wide speed range between 1,500 and 6,000 rpm. Engine management developed to the highest standard of excellence is obviously essential to provide such qualities and, indeed, leadership in so many crucial disciplines. Precisely this is why the six cylinders come with MS45 engine control masterminding not only the main functions of the engine as such, but also other functions such as on-board power management with an intelligent battery sensor, the comfort start mode on automatic transmission models, and automatic cruise control. The six-cylinder power units in the BMW 5 Series feature an all-electronic throttle butterfly dosing the driver??????????????????????????????????????s commands (= use of the gas pedal) even more sensitively in stop-and-go traffic and ensuring an immediate response of the car whenever the driver requires maximum power: The system ???????????????????????????????????sees???????????????????????????????? which gear is currently in mesh and is therefore able to activate an individually programmed throttle butterfly control line for each gear increment. The same convenience is also offered when driving with cruise control, which is again integrated in its functions in the electronic throttle butterfly. Through their fundamental design and construction, the six-cylinder power units also prove how much attention BMW gives to the question of all-round economy in the configuration of engines:

• Like the ancillary units driven by a ribbed V-belt, the camshaft chain drive is maintenance-free for the entire life of the engine.
• The air filters and long-life spark plugs only have to be replaced after approximately 100,000 kilometres when driving under normal conditions.
• The average oil change interval is approximately 24,000 kilometres or 15,000 miles, and may, under appropriate conditions, be extended up to 30,000 kilometres or 19,000 miles.
• Whilst the engine is built for 98 octane fuel, it is able to recognise all fuel grades between 91 and 98 octane and will not suffer even when driven consistently with 91 octane fuel. Like on all BMW petrol engines, anti-knock control automatically adjusts the engine??????????????????????????????????????s running parameters to the fuel grade currently used.
• The exhaust system is made of stainless steel fully welded all round to virtually eliminate any risk of corrosion. The Service Interval Indicator, a BMW invention now enhanced to an even higher standard, offers the driver additional information on
• residual mileage up to the next oil change (in kilometres or miles, depending on national specifications)
• the month and year in which service is required next
• possible expiry of the period allowed for service.

Six-cylinder diesel engine Introducing the 530d, BMW now offers a genuine power diesel in the executive class: The straight-six diesel within the engine compartment so far only available in the 7 Series with this kind of power and performance is one of the most powerful high-performance six-cylinder diesel engines in the world. This represents an increase in output by well over 12 per cent and a boost in torque by 22 per cent over the previous model. Together with the introduction of six-speed transmission and the wide range of weight-reducing improvements, this extra power serves to shorten the time required for accelerating from 0???????????????????????????????????????100 kilometres/h by 0.7 seconds to 7.1 (7.3) seconds and to increase top speed by 15 (13) kilometres/h to 245 (243) kilometres/h or 152 (151) mph. At the same time fuel consumption is down by 0.2 (0.5) litres to 6.9 (7.8) litres/100 kilometres or 40.9 (36.2) mpg Imp in the EU combined cycle (figures in brackets for automatic transmission model). This exemplary combination of superior output and torque with equally superior fuel efficiency and unparalleled refinement is based on the straight-six design principle featuring second-generation common rail fuel injection. The common rail, as the name indicated, is a common pressure vessel for all cylinders supplying the injection jets with compressed fuel. The currently most advanced system operates at a system pressure of 1,600 bar and features volume control to speed up the injection process and atomise the fuel injected even more efficiently in the interest of enhanced performance and greater fuel efficiency. Instead of constantly compressing the entire volume of fuel supplied to maximum pressure, the new system with volume control compresses only as much fuel as is currently required. The reduction of energy in the high-pressure pump achieved in this way makes a significant contribution to reducing fuel consumption, micro-hole injection jets with optimised jet openings serving at the same time to atomise the fuel with maximum efficiency. With the system being able to inject fuel several times per operating cycle, the conflict of interests between power, performance and noise control is solved even more efficiently than before, fuel now being injected up to four times per operating stroke in a double-pilot, main and post-injection process. Whilst double-pilot injection makes the entire combustion process even softer and more harmonious, post-injection reduces particle oxidation and cuts back emissions of harmful pollutants at the same time, giving the driver of the 530d two important benefits in one: The engine is even quieter and more comfortable and burns fuel with optimum emission management. So it is no surprise that the new diesel saloon easily outperforms the EU3 emission standard. Digital Diesel Electronics with engine smoothness management and 6,000 control maps To capitalise on the potentials offered in particular by the latest generation of common rail technology, BMW??????????????????????????????????????s specialists have further enhanced Digital Diesel Electronics in the DDE5 generation with 32-bit architecture, 1.5-megabyte memory, and operating cycle frequency of 40 megahertz. DDE5 is also able to process the commands sent to the automatic cruise control. Quick and convenient:
Automatic, spontaneous engine start without preheating DDE5 also masterminds the rapid-heating system using electronically controlled 6-volt low voltage spark plugs with only the tip raised to maximum temperature and therefore offering spontaneous engine starting characteristics, higher terminal temperatures, greater efficiency by reducing power uptake to a minimum, and more compact dimensions. The engine can start immediately at temperatures down to 5 ????????????????????C, and takes just two seconds to fire in very cold temperatures down to ???????????????????????????????????????20 ????????????????????C. Six-speed transmission Engine power in all new 5 Series Saloons is transmitted to the wheels by six-speed transmission ??????????????????????????????????????? either by a manual gearbox featured as standard or by automatic transmission available as an option. The newly developed manual gearbox gives the driver five benefits in one: even more dynamic power, superior economy and comfort combined with a smooth and simple gearshift, as well as optimum precision when shifting gears. Sixth gear increases the overall range of gear increments and allows the driver to capitalise on engine power both when accelerating and at top speed. The gear increments vary according to the engine, the 520i and 530i each reaching their top speed in fifth gear. Then, shifting to the highest gear, engine speeds are reduced and the engine becomes quieter, with road speed slightly decreasing. Sixth gear therefore serves as an overdrive or economy gear in the spark ignition models, whilst in the 530d it is the ???????????????????????????????????fastest???????????????????????????????? gear giving the car its top speed, since here the focus in the development process was on superior performance. As precise and smooth as it already was, the previous gearshift has been thoroughly upgraded and enhanced to provide an even more comfortable and precise experience of shifting gears. All 5 Series are available as an option with automatic transmission again with six gears in all cases: The new 6HP19 transmission on the 520i and 530i extends the range of the six-speed automatic transmission introduced in the 7 Series as the first transmission units of this type in the world. The 530d, in turn, comes with the 6HP26 transmission, which already made its debut in the 730d, where it is fitted as standard. Using a Lepelletier gearset and benefitting from consistent lightweight construction, the new 6HP19 is 8, the 6HP26 even 14 kilograms lighter than the respective previous models with five gears. And at the same time the total range of gear increments covered is up by 22 and, respectively, 35 per cent. Again interacting with the improved standard of engine efficiency, this benefits both fuel economy and dynamic performance, the modular construction system allowing use of many shared parts, with only the components conveying engine torque being modified accordingly. In conjunction with automatic transmission the 5 Series now also features BMW??????????????????????????????????????s comfort start function requiring only a short start signal from the ignition key to trigger the largely automatic starting process. Built for dynamic performance:
Final drive, propeller shaft, wheel drive shafts BMW is the only car maker in the world to use an aluminium propeller shaft for the ongoing transmission of power. The main reason for this superior technology is the reduction of weight, the lightweight shaft saving more than three kilograms versus a steel shaft. And since the bolted connections are still made of steel for reasons of strength and stability, BMW has developed a special friction welding technology to ensure low-cost and efficient production. Efficient use of energy was also the crucial factor in designing the final drive and choosing the right configuration, with a different transmission ratio for each combination of engine and transmission. Indeed, this harmony of transmission provides the final touch in balancing the entire powertrain, offering yet again an even higher standard of dynamic performance together with superior fuel economy. Reduction of weight was also the name of the game when focusing on the wheel drive shafts: The shafts connecting the individual joints used to be solid inside. Now a newly developed technology allows the wall thickness of the hollow shafts to be adjusted exactly to the exterior diameter. Such hollow shafts not only save up to one kilograms, but also reduce unsprung masses and improve roll comfort accordingly.