BMW F11 Service Training

Technical�training.

Product�information.

BMW�Service

F11�Body.

General�notes

Symbols�used

The�following�symbol/pictograph�is�used�in�this�document�for�better�understanding�or�to�emphasize

particularly�important�information:

Contains�important�safety�tips�and�information�required�for�proper�system�function,�which�must�be

observed�under�all�circumstances.

Topicality�and�national�versions

BMW�Group�vehicles�are�designed�to�meet�the�highest�safety�and�quality�requirements.�Changing

requirements�in�areas�such�as�environmental�protection,�customer�benefit,�design�and�construction

lead�to�continuous�advancement�of�systems�and�components.�This�can�result�in�deviations�between

the�information�contained�in�this�document�and�the�vehicles�available�for�training.

This�document�describes�European�version�vehicles�with�left-hand�drive�as�a�matter�of�principle.�In

vehicles�with�right-hand�drive�some�controls�and�components�may�be�arranged�differently�than�shown

in�the�illustrations�in�this�document.�Other�deviations�may�result�from�equipment�versions�for�specific

markets�or�countries.

Additional�information�sources

Further�information�on�the�individual�subjects�is�given:

• in�the�operating�instructions

• in�the�Integrated�Service�Technical�Application:

Contact:�conceptinfo@bmw.de

Reproduction,�in�whole�or�in�part,�is�permissible�only�with�written�approval�of�BMW�AG,

Munich.

The�information�contained�in�this�document�is�a�part�of�the�BMW�Group�Technical�Training�Program

and�is�intended�for�trainers�and�participants�in�this�program.�Changes/supplements�to�the�technical

data�are�given�in�the�current�BMW�Group�information�system.

Information�status:�June�2010

VH-23/International�Technical�Training

F11�Body.

Contents

1. Introduction............................................................................................................................................................................................................................................5

1.1. The�new�BMW�5�Series�Touring.................................................................................................................................................. 5

1.1.1. Dimensions.....................................................................................................................................................................................5

1.1.2. Silhouette�comparison.................................................................................................................................................7

2. Body......................................................................................................................................................................................................................................................................8

2.1. Body�shell.......................................................................................................................................................................................................................... 8

2.1.1. Introduction....................................................................................................................................................................................8

2.1.2. Materials..............................................................................................................................................................................................9

2.1.3. Corrosion�protection�and�sealing........................................................................................................... 11

2.1.4. Front�end.......................................................................................................................................................................................13

2.1.5. Side�frame................................................................................................................................................................................... 14

2.1.6. Roof........................................................................................................................................................................................................14

2.1.7. Rear�end......................................................................................................................................................................................... 15

2.1.8. Rear�panel....................................................................................................................................................................................16

2.2. Pedestrian�protection..................................................................................................................................................................................16

2.2.1. Active�engine�hood....................................................................................................................................................... 16

2.3. Doors..................................................................................................................................................................................................................................... 18

2.4. Rear�hatch.....................................................................................................................................................................................................................20

2.4.1. Rear�hatch�operating�concept..................................................................................................................... 22

2.4.2. Hear�window�operating�concept..............................................................................................................22

2.5. Panorama�glass�roof..................................................................................................................................................................................... 22

2.5.1. Dimensions................................................................................................................................................................................ 24

2.6. Strength............................................................................................................................................................................................................................ 24

2.7. Accident�research.............................................................................................................................................................................................26

2.7.1. Preventative�measures............................................................................................................................................ 26

2.7.2. Safety�tests/accident�analysis......................................................................................................................28

2.7.3. Head-on�collisions..........................................................................................................................................................29

2.7.4. Side�collision........................................................................................................................................................................... 30

2.7.5. Rear�end�collision............................................................................................................................................................ 33

2.7.6. Pedestrian�protection................................................................................................................................................ 34

3. Exterior�and�interior�equipment................................................................................................................................................................... 36

3.1. Exterior�equipment..........................................................................................................................................................................................36

3.1.1. Front�end.......................................................................................................................................................................................36

3.1.2. Rear�bumper............................................................................................................................................................................ 37

3.1.3. Roof�railing.................................................................................................................................................................................. 37

3.1.4. Underbody�concept..................................................................................................................................................... 37

3.2. Interior�equipment............................................................................................................................................................................................38

3.2.1. Dimensions................................................................................................................................................................................ 38

3.2.2. Instrument�panel............................................................................................................................................................... 38

F11�Body.

Contents

3.2.3. Center�console:...................................................................................................................................................................41

3.2.4. Front�storage�features..............................................................................................................................................42

3.2.5. Rear�storage�features................................................................................................................................................ 44

3.2.6. Front�seats..................................................................................................................................................................................45

3.2.7. Rear�seats.................................................................................................................................................................................... 51

3.2.8. Air�conditioning................................................................................................................................................................... 53

3.3. Luggage�compartment............................................................................................................................................................................. 55

3.3.1. Luggage�compartment�roll-up�cover................................................................................................57

3.3.2. Dimensions................................................................................................................................................................................ 59

F11�Body.

1.�Introduction.

5

1.1.�The�new�BMW�5�Series�Touring.

The�F11�will�be�introduced�on�the�market�in�September�2010.�The�models�523i�and�535i�will�be

offered�with�gasoline�engine.�Models�520d�and�350d�will�be�equipped�with�diesel�engines.

BMW�5�Series�Touring

1.1.1.�Dimensions

BMW�5�Series�Touring,�outer�dimensions

Index Explanation Value

a

Vehicle�height,�unladen

1

[mm] 1462

b Track,�front,�with�basic�wheels [mm] 1600

c Front�overhang [mm] 832

d Wheelbase [mm] 2968

e Rear�overhang [mm] 1107

F11�Body.

1.�Introduction.

6

Index Explanation Value

f Track,�rear,�with�basic�wheels [mm] 1626

g Vehicle�length [mm] 4907

h Vehicle�width�not�including�exterior�rear�view

mirrors.

[mm] 1860

1

�With�roof�antenna.�1488�mm

Comparison�F10/F11/E61

F10 F11 E61

Vehicle�height,�unladen [mm] 1464

1462

1

1491

Track,�front [mm] 1600 1600 1558

Front�overhang [mm] 832 832 852

Wheelbase [mm] 2968 2968 2886

Rear�overhang [mm] 1099 1107 1105

Track,�rear [mm] 1627 1626 1581

Vehicle�length [mm] 4899 4907 4843

Vehicle�width�not�including�exterior�rear�view

mirrors.

[mm] 1860 1860 1846

Vehicle�width�including�exterior�rear�view�mirrors. [mm] 2094 2093 2030

Turning�circle�(unladen) [m] 11.95 11.95 11.4

Front�shoulder�room [mm] 1480 1480 1456

Rear�shoulder�room [mm] 1427 1427 1454

Front�elbow�room [mm] 1518 1518 1484

Front�elbow�room [mm] 1485 1486 1496

Maximum�front�head�room [mm] 1028 1028 1027

Maximum�rear�head�room [mm] 973 993 994

Luggage�compartment�volume [liters] 520 560–1670 500–1650

1

�With�roof�antenna.�1488�mm

Weights�and�payload

Weights�in�compliance�with�DIN�for�F11�and�E71,�European�version�and�payloads�are�given�in�the�table

below:

F11�Body.

1.�Introduction.

7

Vehicle Curb�weight�(DIN)

Automatic�/�manual�transmission

Payload

F11�523i [kg] 1730�/�1715 650

E61�525i [kg] 1630�/�1605 600

F11�535i [kg] 1770�/�1765 650

E61�530i [kg] 1630�/�1620 600

F11�520d [kg] 1715�/�1710 650

E61�520d [kg] 1620�/�1600 600

F11�530d [kg] 1805�/�1800 650

E61�530d [kg] 1700�/�1660 600

1.1.2.�Silhouette�comparison

F11�Silhouette�comparison�with�BMW�5�Series�Touring�E61

F11�Body.

2.�Body.

8

2.1.�Body�shell

F11�Body�shell

2.1.1.�Introduction

On�the�F11�great�value�was�also�placed�on�light�weight�construction.�This�was�implemented�by

intelligent�use�of�high�strength�multi-phase�steels�and�high�strength�hot�formed�steels.�On�the�F11�the

average�strength�of�the�body�materials�has�increased�by�37�%�in�comparison�to�the�E61.

The�light�weight�material�significantly�reduces�the�vehicle�weight�and,�in�combination�with�a�stiff�body

skeleton,�provides�a�considerable�contribution�to:

• Driving�stability

• Fuel�economy

• Reduction�of�CO

2

emissions

• Passive�safety.

F11�Body.

2.�Body.

9

Highlights

• Cast�aluminum�suspension�strut�dome

• High�percentage�of�multi-phase�steels�(20%�of�weight�of�body�skeleton).

• High�percentage�of�hot�formed�steels�(9�%�of�weight�of�body�skeleton).

The�load-optimized�component�design�of�the�cast�aluminum�suspension�strut�domes�reinforces

the�front�end.�In�comparison�to�conventional�steel�shell�design,�the�compact�design�has�significantly

reduced�the�space�requirements�and�decreased�the�weight�in�the�front�end.�This�has�led,�among�other

things,�to�more�uniform�axle�load�distribution.

The�high�strength�multi-phase�steels�and�high�strength�hot�formed�steels�ensure�low�weight�while

providing�maximum�strength�for�the�passenger�safety�cell�thus�contributing�to�the�passive�safety�to�a

high�degree.

An�innovative�advancement�in�the�form�of�passive�corrosion�protection�is�used�on�the�hot�formed

steels.�Until�now�suitable�hot�formed�sheet�metal�materials�with�cathodic�corrosion�protection�were

not�available�on�the�market.�Development�of�press�hardening�technology�has�provided�a�mass

production�process�for�production�of�galvanized,�hot�formed�components.

With�this�process�galvanized�sheet�metal�is�first�cold�formed�and�then�heated�to�a�temperature�of

approx.�900�°C.�Immediately�thereafter�the�components�are�cooled�down�to�approx.�70°C�within

seconds�directly�in�the�water�cooled�pressing�tools,�hardening�the�components.�This�process

produces�components�with�a�minimum�yield�strength�significantly�greater�than�1000�MPa.

Components�produced�in�this�manner�can�be�used�in�wet�areas�without�any�corrosion�to�the�base

material.�Additional�corrosion�protection�measures�are�eliminated�for�such�steel.

2.1.2.�Materials

Modern�automotive�bodies�must�satisfy�many�requirements.�In�spite�of�minimum�outer�dimensions

they�must�provide�the�largest�possible�interior�space.�Passengers�must�be�protected�optimally�against

injury�in�the�event�of�an�accident.�The�torque�generated�by�all�assemblies�such�as�the�engine�and

transmission�is�supported�by�the�body.�Moreover�the�body�must�provide�high�static�and,�above�all,

dynamic�rigidity�to�guarantee�the�exceptional�driving�characteristics�typical�for�BMW.

Last,�but�not�least,�the�supporting�structure�of�the�vehicle�must�have�high�fatigue�strength�and�be

capable�of�repair�at�reasonable�expense�in�the�event�of�an�accident.

To�satisfy�all�of�these�requirements�optimally,�BMW�pursues�a�strategy�of�producing�every�component

using�the�material�best�suited�for�the�specific�function.

The�two�terms,�aluminum�and�steel,�are�only�the�generic�terms�for�a�variety�of�alloys�with�highly

differing�properties.

F11�Body.

2.�Body.

10

F11�Body�shell�materials

Index Explanation

1 Multi-phase�steels�(>�300�MPa)

2 Hot�formed�steels�(>�900�MPa)

3 Aluminum

4 Other�steels�(>�300�MPa)

Multi-phase�steels�are�steels,�whose�structure�consists�of�a�number�of�phases.�High�strength�multi-

phase�steels�with�a�yield�strength,�R

p0.2,

�between�300�and�600�MPa�include,�for�example,�dual-phase

steels�or�TRIP�steels.�High�strength�multi-phase�steels�with�a�yield�strength,�R

p0.2,

�greater�than�600

MPa�include,�for�example,�complex�steels�or�martensite�phase�steels

Hot�formed�manganese-boron�steels�are�high�strength�steels�with�a�yield�strength,�R

p0.2,

�greater�than

900�MPa.

Percentages�by�weight

The�percentage�of�high�and�maximum�strength�multi-phase�steel,�high�strength�hot�formed�steel�and

aluminum�is�increasing�to�reduce�vehicle�weight�while�simultaneously�guaranteeing�maximum�body

strength.

F11�Body.

2.�Body.

11

F11�Body�shell,�distribution�of�materials

Index Explanation

1 Multi-phase�steels�(>�300�MPa)�Percentage�20%

2 Hot�formed�steels�(>�900�MPa)�Percentage�9%

3 Aluminum,�Percentage�2%

4 Other�steels�(<�300�MPa)�Percentage�69�%

2.1.3.�Corrosion�protection�and�sealing

Galvanized�sheet�metal�and�aluminum�or�aluminum�sandwich�panels�are�used�primarily�on�the�F11

body�to�optimize�corrosion�protection.�Joining�technologies�include�welding,�gluing�and�riveting.

Sheet�metal�overlaps�are�laid�out�to�minimize�abutting�surfaces.�This�helps�prevent�creep�corrosion.

The�body�structure�is�designed�to�prevent�water�penetration�by�gluing�and�sealing�the�joined�surfaces.

In�particularly�critical�areas,�expanded�foam�parts�are�used�to�seal�hollow�cavities�in�the�body�against

moisture.�Double�layers�of�sheet�metal�in�wet�areas�are�double�sealed,�and,�if�necessary,�preserved

additionally�with�wax.

F11�Body.

2.�Body.

12

Overlapping�layers�of�sheet�metal�in�dry�areas�are�sealed�where�necessary�to�prevent�dust�from

entering.

Contact�is�avoided.�between�different�types�of�materials,�which�are�critical�in�terms�of�corrosion.�The

combination�of�material�substrates�and�joining�procedures�is�matched�carefully�to�prevent�corrosion

risks.

Coating�process

During�the�painting�process�the�body�shell�is�immersed

• in�an�alkaline�bath�for�cleaning

• phosphated�(surface�roughened�up�for�better�adhesion)

• coated�using�a�catalytic�immersion�process�(coated�with�corrosion�protection�paint�on�inside

of�all�hollow�body�cavities).

The�organic�finish�paint�is�then�baked�on.

Moreover�the�body�is�sealed�with�PVC�and�the�outer�surface�protected�with�filler,�top�coat�and

transparent�paint.

Particularly�critical�body�areas�on�the�F11�are�protected�by�systematic�hollow�cavity�preservation.

The�objectives�are:

• Five�years�without�any�visible�corrosion�to�the�body�surface

• Three�years�without�any�visible�corrosion�in�the�underbody�area

• Twelve�years�without�any�panels�rusting�through

• Seal�against�water�and�dust

F11�Body.

2.�Body.

13

2.1.4.�Front�end

F11�Front�end

Index Explanation

1 Right�rear�strut

2 Left�rear�strut

3 Left�front�strut

4 Right�front�strut

Aways�observe�the�repair�instructions�when�removing�or�installing�struts.

The�struts�increase�the�rigidity�of�the�front�end.

Repair�to�the�front�end�does�not�present�any�grave�differences�in�comparison�to�the�F10.

F11�Body.

2.�Body.

14

2.1.5.�Side�frame

F11�Separation�points�for�repair

The�separation�points�shown�above�should�be�used�preferably�for�repair.

F11�Replacement�part�sections

The�rear�side�panel�is�welded�to�the�body�shell�at�the�factory.�When�repairing�the�rear�side�panel�can�be

glued�and�riveted.

2.1.6.�Roof

The�roof�is�welded�to�the�body�shell�at�the�factory.�When�repairing�the�roof�can�be�glued�and�riveted.

F11�Body.

2.�Body.

15

2.1.7.�Rear�end

F11�Rear�end

Repair�to�the�rear�end�does�not�present�any�grave�differences�in�comparison�to�the�F01.

F11�Body.

2.�Body.

16

2.1.8.�Rear�panel

Rear�panel

The�rear�panel�is�welded�to�the�body�shell�at�the�factory.�When�repairing�the�rear�panel�can�be�glued

and�riveted.

2.2.�Pedestrian�protection

A�number�of�pedestrian�protection�features�are�installed�on�the�front�end�of�the�F11.�A�shock�absorber

is�installed�between�the�bumper�support�and�bumper�trim�to�protect�against�leg�impact.�The�engine

hood�and�front�side�panels�are�made�of�aluminum�and�equipped�with�deformation�elements.�This

design�is�intended�to�absorb�the�energy�in�a�defined�manner�in�the�event�of�an�accident.

2.2.1.�Active�engine�hood

An�active�engine�hood�is�installed�depending�on�the�national�version.�In�the�event�of�a�collision�with�a

pedestrian,�the�hood�lifts.�This�provides�a�deformation�zone�to�protect�the�pedestrian.

When�working�on�engine�hood�hinges�and�engine�hood�latches�observe�the�repair�instructions.

Otherwise�unintended�actuation�could�pose�an�injury�hazard.

F11�Body.

2.�Body.

17

F11�Active�engine�hood

Index Explanation

1 Right�engine�hood�latch�(with�actuator)

2 Left�engine�hood�latch�(with�actuator)

3 Bowden�cable

4 Left�engine�hood�hinge�(with�actuator)

5 Right�engine�hood�hinge�(with�actuator)

6 Fiber�optic�cable

7 Actuator�(on�engine�hood�hinge)

8 Sensor

9 Interference�structure

A�fiber�optic�cable�is�integrated�between�the�bumper�support�and�the�shock�absorber.�The�fiber�optic

cable�is�connected�to�a�sensor�and�runs�back�to�the�sensor�over�a�loop�on�the�opposite�side�of�the

vehicle.

F11�Body.

2.�Body.

18

The�force�acting�on�the�fiber�optic�cable�causes�it�to�deform�between�the�interference�structures.

This�attenuates�the�light�conducted�by�the�fiber�optic�cable.�The�effective�force�is�proportional�to�the

attenuation�of�the�light.�The�different�attenuation�of�the�light�depending�on�the�mass�and�rigidity�of�the

colliding�object�generates�a�characteristic�signal.

This�signal�is�measured�by�the�sensor�and�transferred�to�the�ACMS�crash�safety�module�over�a�data

line.�The�ACMS�crash�safety�module�determines�from�this�data,�whether�the�threshold�for�recognition

of�a�collision�with�a�pedestrian�has�been�reached�or�exceeded�thereby�allowing�a�decision�to�be�made

to�activate�the�actuators�on�the�engine�hood.

The�actuators�are�activated�by�pyrotechnic�devices�raising�the�engine�hood�using�the�spring�force�of

the�integrated,�pretensioned�springs.

The�active�engine�hood�is�activated�only�at�speeds�of�approx.�20�-�50�km/h.�For�safety�reasons�the

system�may,�in�rare�cases,�activate�even�when�a�collision�with�a�pedestrian�cannot�be�clearly�excluded,

e.g.:

• Impact�with�a�barrel�or�marking�post

• Collision�with�animals

• Stone�impact

• Driving�into�a�snow�drift.

After�actuation�of�the�active�engine�hood�a�red�warning�triangle�illuminates�in�the�instrument�cluster

and�a�check�control�message�appears�in�the�central�information�display.�The�engine�hood�can�then�be

moved�back�to�its�initial�position,�however�the�active�pedestrian�protection�is�again�available�only�after

component�replacement.

Returning�engine�hood�to�initial�position

• Pull�engine�hood�lever

• Press�release�lever�and�open�engine�hood

• Open�engine�hood�all�the�way�to�the�end�position.

The�actuators�on�the�engine�hood�hinges�should�close�and�lock�completely.

• Move�engine�hood�back�and�drop�from�height�of�approx.�40cm;�press�to�lock�completely.

The�engine�hood�should�catch�audibly�on�both�sides.

2.3.�Doors

As�on�the�F01,�the�doors�installed�on�the�F11�consist�of�an�aluminum�shell�construction.

F11�Body.

2.�Body.

19

F11�Front�and�rear�doors

F11�Aluminum�shell�door�structure

Large�aluminum�shells�capable�of�transferring�high�forces�in�area�of�the�door�structure�guarantee

maximum�rigidity�and�component�quality�with�minimum�tolerances.�Realization�of�a�high�drawing

depth�and�new�component�separation�points�(hinge�reinforcement�and�inner�door�panel)�allow

implementation�of�the�attractive�design�on�the�exterior.

The�window�frame�area�satisfies�the�highest�demands�for�rigidity�using�channels�consisting�of�only

two�sheet�metal�parts�with�minimum�dimensions�and�simultaneous�production�efficiency.�BMW�has

succeeded�in�implementing�its�typical�exterior�appearance�even�in�the�visually�sensitive�area�of�the

window�frame.

Advantages:

• Reduced�CO

2

emissions�and�increased�stability�through�weight�reduction.

(approx.�23�kg�per�vehicle�in�comparison�to�previous�steel�version).

• Interior�impression�with�improved�feeling�of�space.

• More�daylight�in�passenger�compartment

• Improved�visibility�to�outside�and�upward

F11�Body.

2.�Body.

20

• Filigree�window�frame�appearance�with�door�closed

• Solid�window�frames�with�high�quality�effect�with�door�open.

• Single-piece�inner�door�panel�in�area�of�door�body�and�window�frame�for�maximum

dimensional�stability�of�individual�parts.

• Minimum�number�of�structural�door�parts.

• Door�structure�joined�by�laser�welding�and�structural�gluing.

Aluminum�door�structures�have�been�used�by�BMW�frequently�in�the�past,�for�example�on�the�E52,

E63,�E74�and�E36�M3.�However�aluminum�doors�have�been�produced�in�high�quantities�for�vehicles

only�since�introduction�of�the�F01.�The�development�target�of�the�door�structure�for�the�F11�was

therefore�to�implement�the�aluminum�door�concept�familiar�from�the�F01�at�acceptable�costs�for�larger

quantities.

However�the�production�of�shell�parts�using�aluminum�sheet�is�considerably�more�demanding�than

with�steel�materials�in�terms�of�the�production�engineering,�particularly�at�high�drawing�depths.

Development�of�a�new�structural�concept�with�large�shells�capable�of�transferring�high�forces�did,

however,�make�production�feasible�without�abandoning�the�proven�sheet�metal�shell�design.

2.4.�Rear�hatch

In�comparison�to�the�E61,�the�luggage�compartment�opening�has�been�increased�even�more.�In

addition�to�the�width,�the�height�of�the�opening�has�been�increased�considerably�by�completely

integrating�the�hinge�mechanism�into�the�roof�surface.

The�individual�rear�hatch�parts�are�steel.

Comparison�between�luggage�compartment�opening�on�F10/F11/E61

Index Explanation

A F11

B E61

An�automatic�rear�hatch�actuation�is�available�as�special�equipment�(SA�316).

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BMW F11 Service Training

BMW F11 Service Training

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