BMW M5 Wartungshandbuch

BMW Service Aftersales TrainingE60 M5Complete vehicleClick to Return to Index or use Browser Back Button

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98FunctionsDynamic Stability Control MK60E5DSC Additional FunctionsCompared to the standard DSC features, theMK60E5 in the E60 M5 has been upgradedby

108Hill ascent assistantAssistance is provided when driving off onuphill gradients by briefly maintaining aspecific brake pressure in the wheel brakes

119System componentsDynamic Stability Control MK60E5Differences compared to the MK60psiThe main differences in the design of theMK60E5 compared to the

129Pressure generation• Pump with two differential piston pumpelements• Operated by means of common eccentricshaft• 250 W pump motor• ASC and DSC mode

ContentsDisplays, Indicators andControlsObjectives1Introduction 3System overview 5System components 7

16ObjectivesDisplays, Indicators and ControlsPurpose of this Participant's ManualThe Participant's Manual is a documentdesigned to accompany

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37IntroductionDisplays, Indicators and ControlsAdditional FunctionsCompared to the 545i, the E60 M5 providesthe driver with additional functions relat

16ObjectivesS85B50 EnginePurpose of this Participant's ManualThe Participant's Manual is a documentdesigned to accompany a seminar while at

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58System overviewDisplays, Indicators and ControlsDifferences compared to the E60The M5 instrument cluster is based on theinstrument cluster of the E6

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79System componentsDisplays, Indicators and ControlsDisplays and indicators in the E60 M5Instrument clusterThe instrument cluster in the M5 is based o

89Oil level indicatorThe M5 is equipped with an electronic oil levelindicator. The oil level is indicated in theinformation field of the on-board comp

99Perform quick measurement• Park vehicle in horizontal position• Engine running at idle speed• Oil temperature above 70 °C• Select engine oil level i

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AbbreviationsACC Active cruise controlBC On-board computerBSD Bit-serial data interfaceCAS Car access systemDME Digital motor electronicsDSC Dynamic s

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37IntroductionS85B50 EngineIntroductionThe S85B50 is the first 10-cylinder enginefrom BMW for series production vehicles. Thehigh speed layout of the

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58System overviewS85B50 EngineS85B50Engine block with bedplateThe lower bearings of the crankshaft inconventional crankcases are designed asindividual

68Bedplate screw connectionThe bedplate is secured to the upper sectionof the crankcase with the main bearing bolts.The positions are fixed with fitte

78Bedplate sealingPrimer is used to harden the liquid sealant atthe outlet points.Crankshaft driveThe forged crankshaft has a crank pinsequence of 72°

88Cylinder headThe one-piece design of the cylinder headoffers advantages with regard to rigidity and areduction in sealing surfaces.Both the idle air

98VANOSAs known from the S62, the VANOS system isused on the S85 to adjust both the intakecamshaft as well as the exhaust camshaft. Theintake camshaft

The information contained in this Participant's Manual is intended solely for participants of theBMW Aftersales Training course.Refer to the late

108The displacement range of the pistons in theVANOS control unit is converted into rotarymotionby an infinitely variable gear mechanismintegrated in

118Belt driveThe water pump and alternator are driven bythe main belt drive. The drive is provided bythe pulley on the crankshaft.The secondary belt d

128Cooling circuitCoolant flows both through the cylinder headas well as the engine block in the familiarcross-flow manner. A new feature, however, is

138Oil circuit lubricationThe S85 is equipped with a quasi-dry sump.For this reason, a suction pump is used topump the oil out of the oil pan in the a

148Intake air manifoldThe S85 is equipped with a separate intake airmanifold for each cylinder bank. The intake airmanifolds are connected via hoses t

158Secondary air systemAfter the engine has been started, the electricsecondary air pump mixes fresh air with theexhaust gas to bring about oxidation

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179System componentsS85B50 EngineBasic engine and add-on partsUpper section of crankcaseThe upper section of the crankcase is madefrom an aluminium al

189Crankshaft/main bearingsThe crankshaft is forged from a high-strengthsteel 42CrMo4 and weighs 21.63 kg. Aftergrinding the bearing points, the shaft

199The specified tightening operation for theconnecting rod bolts must be adhered toprecisely. Tightening the bolts three times tothe same tightening

Participant's ManualE60 M5 - Complete vehicleS85B50 engineDigital motor electronics (DME) S85B50Sequential M gearbox (SMG 3)Dynamic stability con

209Box-type tappetsCompared to bucket tappets, box-typetappets permit a substantially greater crowncurvature, resulting in decreased migration ofthe c

219The high pressure pump consists of the fixedstator about which the rotor rotates. Fivemoving plungers are mounted in the rotor. Thestator and rotor

229VANOS ActuatorsSeparate adjustment units are provided foreach cylinder bank for the purpose ofadjusting the VANOS gear mechanism. Theseadjustment u

239The holding function and piston retraction areachieved by reducing the oil feed on the sidewith the largest piston surface area by partlyactuating

249The actuator (adjustment unit) is connected tothe outer and inner sleeve by the screwconnection of the gear mechanism. Duringadjustment, the inner

259The exhaust camshaft is driven by the intakecamshaft in connection with a gear drivemechanism. The drive gearwheel is split in twoin order to avoid

269VANOS Pressure accumulatorThe pressure accumulator is preloaded withnitrogen. A piston separates the oil chamberfrom the gas chamber.The VANOS oper

27922 - Minimum delivery23 - Maximum delivery

289Electric oil pumpsWhen cornering at high speeds, thecentrifugal force forces the engine oil into theouter cylinder head so that it can no longerflo

299Intake air manifoldThe S85 features a separate intake airmanifold for each cylinder bank that ismounted with hose clips on the throttle valveassemb

309RadiatorThe radiator of the S85 is divided into an upperand a lower water tank. The lower water tankserves the purpose of cooling the coolant fromt

ContentsDME S85B50Objectives1Introduction 3System overview 5Functions 7Functional Principle of the Digital MotorElectronics7System components 15Digita

14ObjectivesDME S85B50Purpose of this Participant's ManualThe Participant's Manual is a documentdesigned to accompany a seminar while at the

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35IntroductionDME S85B50IntroductionThe S85B50 engine can develop a poweroutput of 373 kW (507 bhp) and a maximumtorque of 520 Nm.To ensure the availa

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56System overviewDME S85B50The MS_S65 is a further development of theMS_S54 (MS_S54 HP, M3 CSL) that wasused to control the S54 in the E46 M3.Addition

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77FunctionsDME S85B50Functional Principle of the Digital Motor ElectronicsEngine torque controlThe EDR satellite serves the purpose ofcontrolling the

ContentsE60 S85 - The New M5System overview1Foreword 1

871 - System circuit diagram EDR

97Requirement-oriented fuel delivery with variable pressureIn order to be able to make fuel at variablepressure available to the enginecorresponding t

107Activation of the fuel pumpsThe DME controls the EKP 1 correspondingto requirements via the electric fuel pumpEKP.The EKP 2 cuts in non-regulated i

117Ionic current measurementFor optimized engine management in terms ofexhaust emission and fuel consumption, it isnecessary to establish as accuratel

127Ionic current representationThe ionic current progression (curve) isdirectly dependent on the cylinder pressureand the ions in the cylinder.General

137Comparison of ionic current curves7 - Normal and knockingcombustionIndex Explanation Index Explanation1 Firing point 5 No knocking2 End of ignition

147Selectivity of maximum engine power outputThe POWER button is a ground switch that ispressed once to enable the maximum enginepower output.The mode

158System componentsDME S85B50Digital Motor Electronics (DME)DME control unit Siemens MS_S65As on the E60 production vehicle, togetherwith the intelli

168Fuel pressure sensorThe fuel pressure sensor is located in the frontleft wheel arch.This sensor measures the current fuelpressure and transfers the

178EKP moduleAs on the E60 Series (8-cylinder and diesel),the EKP module is located on the rear right inthe luggage compartment. The power outputstage

188Oil pressure switchThe signal from this switch is transferred tothe DME where it is evaluated. In the event ofa deviation from the specified value,

198Idle speed actuator (LLS)The two idle speed actuators LLS aredesigned as throttle valve actuators and arelocated in the V-area.The idle speed actua

208Throttle valve actuator motorOne actuator motor (EDR) moves fivemechanically coupled throttle valves on eachcylinder bank.Each EDR consists of an a

218Throttle valve sensor (DKG)Two potentiometers are activated per cylinderbank:• One potentiometer for the position control.It is powered and read by

228Mini HFM for secondary air systemA mini HFM measures the secondary air massin the intake pipe of the secondary air pump.This monitoring facility ha

239Service informationDME S85B50Electric throttle valve actuators (EDR)The two EDRs can be used individually.Following replacement, the limit stops mu

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ContentsSequential M gearboxSMG 3Objectives1Introduction 3System overview 5Functions 13System components 15Service information 21

14ObjectivesSequential M gearbox SMG 3Purpose of this Participant's ManualThe Participant's Manual is a documentdesigned to accompany a semi

19System overviewE60 S85 - The New M5ForewordThe new BMW M5 will be launched inOctober 2004. It will be the most powerful M5of all time and the first

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35IntroductionSequential M gearbox SMG 3New 7-speed SMGA new 7-speed sequential M gearbox (SMG)has been developed for the E60 M5. TheSMG 3 is designat

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56System overviewSequential M gearbox SMG 3The new SMG 31 - Selector lever and head-up display in the E60 M5

662 - Schematic circuit diagram SMG

76Index Explanation1 Light module2 Car access system (CAS)3 SMG control unit4 Sequential M transmission5 Pump relay6 Multifunction steering wheel (MFL

863 - Hydraulic circuit diagram SMG 3

96Index Explanation1 Hall sensors, selector rod R/1 (redundant)2 Working piston3 Shift range valve4 Hall sensors, selector rod 5/35 Working piston6 Sh

1064 - SMG 3Index Explanation1 Gearbox breather2 Proportional valves3 Sensor strip4 Shift range valves5 Crankshaft sensor6 Speed sensor, countershaft7

1165 - SMG 3Index Explanation1 Clutch slave cylinder2 Return line3 High-pressure line4 Oil level/filler plug5 Reservoir6 Pressure sensor7 Temperature

29Technical data and competitorsBMWM5 (E60)MercedesE55 AMGAudiRS6 plusLength (mm) 4855 4818 4858Width (mm) 1846 1822 1850Height (mm) 1469 1412 1425Whe

1266 - Two-disc clutchIndex Explanation1 Drive plate2 Intermediate plate3 Drive plate4 Contact plate5 Formed spring6 Pressure plate

137FunctionsSequential M gearbox SMG 3Special functionsTow-startThe following procedure must beimplemented to activate this function:• With the brake

147Clutch overload protection (KÜS)The clutch overload protection function (KÜS)protects the clutch from thermal overload.The clutch overload protecti

158System componentsSequential M gearbox SMG 3Transmission ratio of the SMG 3The SMG 3 is designed as an overdrivegearbox as can be clearly seen in th

168Gearshift pattern2 - Selector rods (top view)Index Explanation Index ExplanationR Reverse 4 4th gear1 1st gear 5 5th gear2 2nd gear 6 6th gear3 3rd

178Signals and parametersGear recognitionThe engaged gear is determined in acontactless arrangement by means of the Hallsensors on the actuators of th

188The PLCD sensor essentially consists of aspecial core made of soft magnetic material.The entire length of the core is enclosed by acoil (primary co

198Steering angleThe signal is tapped off from the CAN. Thisvalue influences the automatic function of thegearbox (gearshift suppression).Longitudinal

208Hydraulic systemA DC motor drives the hydrostatic pump. Thepump conveys the hydraulic oil via a non-return valve into a pressure system whileenergy

219Service informationSequential M gearbox SMG 3InitializationAs on the SMG 2, the SMG control unit mustnewly adapt and store various parametersafter

ContentsS85B50 EngineObjectives1Introduction 3System overview 5System components 17

229Pressure accumulator preloadA function for checking the accumulatorprepressure has been implemented tofacilitate diagnosis for service applications

ContentsDynamic Stability ControlMK60E5Objectives1Introduction 3System overview 5Functions 9System components 11

15ObjectivesDynamic Stability Control MK60E5Purpose of this Participant's ManualThe Participant's Manual is a documentdesigned to accompany

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36IntroductionDynamic Stability Control MK60E5MK60E5 from Continental TevesThe E60 M5 is equipped with the ContinentalTeves Dynamic Stability Control

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57System overviewDynamic Stability Control MK60E5Further development of the MK60psiThe MK60E5 is a further development of theMK60psi, which is current

67Hydraulics diagram DSC MK60E51 - Hydraulics diagram DSC MK60E5

77Index Explanation1 Brake fluid reservoir2 Rear axle3 Front axle (hydraulic connection)4 Pressure sensor, push rod circuit5 Pulsation damper6 Isolati