7
E60 Complete Vehicle
System Components
Body Structure
The body dimensions have been increased to improve roominess in the rear compartment
(+ 5 cm knee room) and to increase the luggage compartment capacity (at 520 L the largest
capacity of all the BMW vehicles including the E65).
In order to make the E60 signifi-
cantly lighter than the current 5
Series, BMW designed a
"reduced-weight aluminum front
end" (GRAV).
The front end consists almost
entirely of aluminum while the
transition to steel occurs in the
front bulkhead area. Aluminum
components are shown in darker
shaded (front clip) section.
The weight saving at the front end not only reduces the total weight of the vehicle but is
also a significant factor in the E60 attaining the ideal axle-load distribution of 50/50.
On the one hand, an aluminum body sec-
tion offers reduced shielding against
external electrical radiation, making it nec-
essary for separate shielding of the wiring
harnesses and electronic control units.
On the other hand, riveted and bonded
aluminum components do not always
provide a guaranteed circuit to ground.
This results in individual front end compo-
nents being connected (in production)
with small EMC safety weld seams and in
the event of repair, with grounding straps.
1. Spring Support
2. Engine Support
3. Bulkhead carrier support
4. Outer connection (steel)
5. Bulkhead Cross Member
6. Bulkhead
7. Inner A-pillar (steel)
KT-11776
KT-11777
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