The 2006 BMW 5 SERIES

6-cylinder models make an early debut with new engines,
new all-wheel drive and a new Sports Wagon

Not even two years after the debut of the current 5 Series – then an all-new platform except for its 6-cylinder engines – this Series of performance/luxury midsize automobiles undergoes a significant update for its 2006 model year. The 6-cylinder models – 525i and 530i Sedans, new all-wheel-drive 525xi and 530xi Sedans, and a new 530xi Sports Wagon – are the first to make their debut, their new model year beginning with March 2005 production. The V-8 model will enter its ’06 model year as of September production.

All the new 6-cylinder models are powered by BMW’s advanced N52 engine, which is also making its debut in the new 3 Series. The new Sports Wagon, an appealing concept combining 5 Series sophistication with enhanced load-carrying versatility, appears in a single all-wheel-drive model.

Five 6-cylinder models for 2006

What else is new for 2006

BMW’s new generation of 6-cylinder engines is designated N52.Compared to its illustrious predecessor, the M54 engine family, the N52 achieves notable progress on all fronts:
• Greater power, 255 vs. 225 hp for the 530i, 215 vs. 184 hp for the 525i. In the case of the 530i, this amounts to an impressive 85 hp per liter.
• Greater torque, 220 lb-ft. vs. 214 in the 530i, 185 lb-ft. vs. 175 in the 525i; and even stronger torque delivery across the broad range of engine speeds.
• Higher revving ability. The new engine’s redline is 7000 rpm, vs. 6500 for the predecessor.
• Fuel efficiency. Though not every model and version is up, there are some impressive gains in EPA mileage ratings: 525i with manual transmission up 1 mpg city/2 mpg highway, with automatic up 2 mpg city/1 mpg highway, 530i automatic up 2 mpg city.
• Reduced weight – 22 lb. less. Had BMW engineers evolved the existing engine to meet their goals, it would have instead added about 30 lb.
• More compact – because there is just one external drive belt vs. the previous two, overall engine length is about an inch less.

Here are some details of how this dramatic progress has been achieved – over an engine that was already outstanding in all these respects.

Valvetronic variable valve lift. This patented innovation, already enhancing the performance and fuel efficiency of BMW’s V-8 and V-12 engines, now appears in a BMW 6-cylinder engine as well – and in evolved form. Valvetronic varies valve lift to a far greater degree than other variable-lift systems – so much, in fact, that it replaces the traditional engine throttle. Engine breathing is controlled entirely by the valves themselves.

The Valvetronic mechanism acts on the intake valves, imposing an additional control element between the camshaft lobe and rocker arm for each cylinder, called an intermediate follower. Upon contact by the lobe, this follower actuates a finger-type rocker arm and, in turn, the valve. The follower’s pivot point is positioned by an eccentric shaft, rotated by a servo motor in response to the driver’s accelerator-pedal movements; this varies the valve lift. The system’s advantages include:
• Greater efficiency. As a throttle closes, it poses a restriction to incoming air. Valvetronic eliminates this restriction, reducing “pumping losses.”
• More spontaneous engine response – again, because there is no conventional throttle.
• More power, because maximum valve lift can be higher than it could be with fixed valve lift.
• A “fatter” torque curve. Not only does the engine produce more torque; the torque peak occurs at a lower speed, 2750 rpm vs. the previous 3500.

Compared to the 1st-generation Valvetronic system of BMW’s V-8s and V-12s, that of the N52 engine has evolved in several ways:
• Higher maximum engine speed, by making Valvetronic reciprocating parts more rigid.
• Maximum valve lift increased, contributing to the increase in power output.
• Greater maximum valve acceleration. Less time is spent opening and closing the valves; thus they are effectively open longer, further reducing pumping losses.
• Phasing of intake valves. A given cylinder’s two intake valves now open at different rates, resulting in a more targeted, asymmetric distribution of the fuel/air mixture that enhances fuel economy under low-load driving conditions.

Additional developments contribute to the new engines’ performance:
• Combustion chambers have been refined.
• BMW’s VANOS variable valve timing has also evolved; the range over which it varies intake-valve timing has been increased by 10 degrees.
• 3-stage induction system (530i engine only). BMW 6-cylinders have long had a 2-stage system, with one intake-path length for lower rpm, the other for higher rpm. By providing an additional “middle” stage, this system further optimizes torque and power delivery.
• Higher fuel-injection pressure, increased from 3.5 to 5 bar (50.8 to 72.5 lb/sq in.), improves the injection spray, reducing emissions from a cold engine.
• All-new engine electronics to optimize engine behavior and performance under all operating conditions.

Unique new magnesium/aluminum composite engine construction
Recent BMW 4-wheel vehicles (i.e. not motorcycles) have utilized three types of engine construction, all with aluminum cylinder heads:
• Regular-production 6-cylinder engines (3, 5, Z4, X3 and X5 Series) – aluminum block with cast-iron cylinder liners.
• V-8 and V-12 engines, new V-10 (5, 7 and X5 Series, M5) – aluminum block with integrally cast silicon-impregnated aluminum cylinder surfaces.
• M3 6-cylinder engine – cast-iron cylinder block.

With the N52 engine, BMW introduces a unique and pioneering engine structure: magnesium/aluminum composite construction, the first in a contemporary automobile. Structurally, the all-new engine block consists of three major castings:
Bedplate (magnesium alloy ). This casting forms the lower portion of the block (crankcase), and is similar in concept to a construction element found in some racing engines – as well as the 500-hp V-10 engine powering the new BMW M5.
Upper crankcase (magnesium alloy3). Joining the bedplate at the level of the crankshaft (main) bearings, this too is a weight-saving casting. Mounted onto the bedplate from above; combines with the bedplate to form the cylinder block’s outer shell. The result is an ultra-rigid, yet remarkably light engine structure.
Insert (aluminum alloy). Forms the cylinders and their coolant passages. Analogous to the entire blocks of BMW‘s V-8, V-10 and V-12 engines, silicon particles are cast into this insert; a “soft honing” machine removes just enough of the aluminum to leave the crystals as ultra-hard cylinder surfaces.

How it goes together. First, the aluminum insert is cast by conventional methods. Then, during a newly developed die-casting method, the magnesium upper shell shrinks onto the insert while cooling; structural rigidity and stability are ensured by interlocking ribs where the two castings meet.

In the next step, the upper crankcase, consisting of magnesium shell and aluminum insert, is mounted onto the magnesium bedplate from above. The sintered-steel main bearings’ lower halves are in place in the bedplate, the upper halves in the upper crankcase. After the bedplate and upper crankcase have been bolted together, a liquid sealing compound is injected into a groove on the contact surface between the two components. Special aluminum bolts are used to attach parts, such as the engine mounting brackets, to the magnesium/aluminum castings.

As the “conventional” part of this construction, the cylinder head is of aluminum; however, the head of an inline 6-cylinder engine must be cast with great precision because its length implies relatively large contraction during the cooling-down process after casting. The casting process used here is called “lost-foam”; because all BMW gasoline engines since the 1960s have had aluminum heads, BMW’s experience in this regard is long and successful; BMW has used the lost-foam method for cylinder heads since 1997. This process, which employs a polystyrene “dummy” of the head to form the mold into which the aluminum is poured, results in an extremely precise casting of this critical engine component.

Other weight-saving materials. Though the magnesium/aluminum composite crankcase construction is the most conspicuous example, other materials and production innovations also help pare weight from the N52 engine. One is the adoption of hollow camshafts, which save a remarkable 2.6 lb. Beginning as steel tubes, the camshafts are shaped in a hydroforming procedure, subjected from the inside to a water pressure of 4000 bar (58,000 lb./sq in.) against outer forms to achieve the cam profiles. All this takes place in a cold state – nothing melts – and as a final step the cams are polished to a finish quality of 1/1000 mm.

The engine’s camshaft cover is of weight-saving magnesium. The VANOS sprockets, via which the camshaft chain drives the two variable-valve-timing mechanisms, are newly of aluminum. And the chain camshaft drive – a high-durability, low-maintenance feature of all current BMW engines – has an aluminum chain tensioner that also saves weight. Instead of being a separate casting, the camshaft drive’s housing is integrally cast into the magnesium structure, eliminating a production step and sealing components. As one final weight-reducing element, the exhaust headers’ flanges are formed from 2-mm-thick steel, significantly lighter than the 12-mm flanges used previously; for a secure seal of this steel to the aluminum head, graphite rings are employed.

Electric coolant pump. A conventional engine coolant (“water”) pump is driven by a belt, and always runs at a speed directly proportional to engine rpm. This innovative feature is electrically driven and electronically controlled according to the engine’s coolant and oil temperatures at any moment. Thus it runs only as much as needed, consuming a maximum of 200 watts vs. up to 2 kilowatts (10 times as much) for a conventional pump. This pump has further benefits:
• By requiring less power, it contributes to the engine’s increased power output.
• Faster engine warmup, because it doesn’t pump when the engine is cold.
• Provides coolant circulation for the climate control’s Heat-at-Rest feature. (With a conventional coolant pump, this needs a separate electric pump.)
• By eliminating an external drive belt, makes the engine shorter.

Variable-volume oil pump. Conventional oil pumps, too, deliver oil in direct proportion to engine speed. In order to supply the VANOS system (which employs oil pressure to vary valve timing) at all speeds and temperatures without excess capacity at high engine speeds, BMW engineers developed a new type of oil pump. By varying the output of its pump element according to engine oil pressure, the engineers achieved a pump that always delivers sufficient pressure to lubricate the engine and operate VANOS, yet never pumps more oil than is necessary. Thus it –
• Contributes to usable power, by requiring less power from the engine.
• Doesn’t require a bypass to divert excess flow, which can be up to 80%. This also avoids possible excess oil temperatures and oil foaming.

Oil/coolant heat exchanger. Another feature that speeds engine warmup; during this phase it transfers heat from the coolant to the oil circuit. Under conditions of high engine power and high oil temperatures, it performs the reverse, transferring heat from the oil circuit to the coolant to remove excess heat.

525i/xi and 530i/xi: the two engine versions
A distinctive engine version powers each set of 5 Series models. Instead of the traditional correlation of model designation to engine size, each is a 3.0-liter N52, but equipped and calibrated for different levels of performance:
• 525i/xi – 215 hp @ 6250 rpm, 185 lb-ft. torque @ 2750 rpm
• 530i/xi – 255 hp @ 6600 rpm, 220 lb-ft. torque @ 2750 rpm.

Significant differences between the 525i/xi and 530i/xi engines are as follows:
• Whereas the 530 engine has the 3-stage induction system, the 525 unit has a single-stage intake manifold.
• Engine software differs between the two models.

5 Series interiors: new materials, refined details
At the beginning of model year ’05, several detail refinements were made to the 5 Series interior:
• The steering-wheel’s leather rim was improved.
• The power windows’ control panel got new Soft Finish.
• Surfaces of interior trim panels were refined.
• In the 545i, the climate control’s rotary knobs were newly in Ruthenium.

Further changes to the Sedan interiors for ’06, which also apply to the new Sports Wagon, are also subtle –
• Adoption of Ruthenium trim for the climate control’s rotary knobs (which regulate temperature and blower speed) and the tabs with which occupants adjust the direction of air from the center-dash outlets. Although the core of this material is plastic, a true metallic surface is applied galvanically in several layers, with a clearcoat on top to protect against corrosion. As one expects with a metallic surface, Ruthenium is cool to the touch. After being applied to the power-window panel for ‘05, Soft Finish now enhances the steering wheel’s spokes – the areas outboard of the wheel’s padded center.
• Leather handbrake grip, replacing leatherette.

Sports Wagon interior and cargo area:
an abundance of thoughtful features
Up front, the Sports Wagon offers essentially the same accommodations as the Sedans. Front and rear leg room are identical for the two body styles; the Wagon’s standard split folding rear seats offer essentially the same functions and benefits as those that are optional in the Sedan.

The big difference, of course, is aft of the rear seats where, in terms of load-carrying ability and versatility, the Sports Wagon offers advantages not only over the Sedans, but also over its predecessor, last offered in ’03. As always with a new BMW – and especially with a new BMW Sports Wagon – the 530xi abounds with rational design and thoughtful details:
• High-lift tailgate – almost 73 in. head clearance – with Soft Close feature. The tailgate is electrically released from the exterior or interior switch or the remote.
• Separately opening rear window, for convenient loading without opening the tailgate.
• Fully lined cargo area – floor, sides, back sides of rear seats – with luxurious, yet long-wearing carpet.
• Wider than that in the previous Wagon, and with straight, essentially vertical sides, the cargo area presents loading capacity as follows:
By European measurement standards –
• 17.6 cu ft. of volume up to the tops of the upright rear seats
• A maximum of 58.3 cu ft., rear seats folded, cargo loaded to ceiling
Official EPA capacity, defined as with the seats upright and cargo loaded to the ceiling:
• 33.6 cu ft.
• Four tie-down hooks in the floor, at the front and rear corners of the compartment.
• A 12-volt accessory power outlet on the right-hand wall.
• An enclosed storage compartment on each side.
• Lockable storage space under the cargo floor, in flocked tray with adjustable dividers to help secure smaller objects. (Spare tire under tray.)
• Instead of having to be hooked into its raised position, the floor rises, and stays in its raised position, on gas struts once released via a convenient handle at the rear of the compartment.
• A cargo net, carried in a roller assembly, that can be mounted with the rear seats either upright or folded. At each side of the cargo area is a flat surface on which this assembly can be slid rearward for removal from vehicle; one does not have to reach in awkwardly and lift the assembly out.
• Cargo cover, concealing cargo when the seats are upright; automatically rises when tailgate is opened and stays up, supported on gas struts. Cover can also be removed from the vehicle.
• If, once raised, a rear-seat backrest is not fully locked into place, a red tab appears to help call users’ attention to it.
• Red light at left side of window opening, for safety.

Dual-panel Panorama Moonroof
Like the Sedans, the Sports Wagon comes standard with a power moonroof; however, the Wagon’s is a dual-panel Panorama Moonroof, a feature also seen in the X3 and X5 Series.

With its overall roof opening of 41.9 x 34.8 in., the Panorama concept gives occupants almost the feeling of being in a convertible. The power glass roof consists of two panels, both of which can be tilted up at the rear. The forward, larger panel can also be slid open; together, their glass area is almost 10 square feet. Although the glass is effectively tinted, there is also a power-operated interior shade; a wind deflector rises at the front of the opening to reduce wind buffeting when panels are open. All motions have 1-touch operation, including that of the interior shade.

Character of the 5 Series:
the essence of sport and luxury
The 5 Series has long been one of BMW’s true core products, elegantly defining the middle of the line with compact exterior dimensions, ample interior space and a masterfully calibrated blend of sport and luxury. Appearing in ’04 in its current generation, the Series maintained trim exterior size while increasing interior space and introducing new technologies – including an aluminum front-end structure, available Active Steering and Active Roll Stabilization, evolved aluminum suspension and an evolved iDrive control system.

That the current generation carries on the 5 Series tradition brilliantly is supported by this quote from Motor Trend’s March 2005 issue: “Here’s a thoroughbred, the product of decades of setting the benchmark all other automakers’ sport sedans aspire to. Just look at the stance, the way the body sits on the chassis, ready to pounce on any opportunity to show its stuff on a challenging stretch of road. The smoothness and flexibility of BMW inline-sixes are legendary, and the 225 horses of the 2979-cc engine seem more spirited than their numbers might otherwise suggest. And BMW is one of the only automakers courageous enough to offer a 6-speed manual gearbox in a $50,000 sedan.”

With its new 6-cylinder engines, available xDrive and the new Sports Wagon to extend its capabilities, the 5 Series now moves on to even greater glory as today’s representative of this fine tradition.

State-of-the-art safety and security features
In terms of safety and security, the 5 Series is a state-of-the-art vehicle from a state-of-the-art vehicle maker. There are no significant changes in this area of the ’06 5 Series – yet with its comprehensive safety features and great substance, the 5 Series remains an industry leader and fully representative of BMW’s safety values. Key features include:
• Dual front-impact Supplementary Restraint System (SRS) with dual-threshold deployment, 2-stage Smart Airbags – optimized for shape and deployment characteristics.
• Front safety belts with automatic tensioners and force limiters – standard on all models.
• Rear safety belts with automatic tensioners – included with the optional rear-seat side-impact airbags.
• Automatic-locking retractors (ALR) on all passenger safety belts for installation of child restraint seats.
• Front-seat side-impact airbags – standard.
• Rear-seat side-impact airbags – optional at nominal extra cost, so that customers can make their own choice in this matter.
• Head Protection System – front-to-rear head protection via BMW’s proven Inflatable Tubular concept; a long tubular airbag deploys from the ceiling and is suspended on a “sail.”
• Active front head restraints – included with the front Comfort seats that are optional in all 5 Series models. Responding to impact sensors at the rear of the vehicle, the head restraints instantly pivot forward into close proximity with the occupants’ heads. Thus occupants are able, if they prefer, to adjust the restraints away from direct contact with their heads, yet gain optimum protection against whiplash or more serious head/neck injuries.
• Energy-absorbing padding of body-pillar and roof areas – specific padding at the A-, B- and C-pillars as well as along the roof above the doors.
• Fuel-tank design and location. Not only is the fuel tank designed to remain sealed even in severe impacts, its location has been chosen to provide optimum protection from impacts.
• Intelligent Safety and Information System (ISIS) – employing 14 sensors to achieve a precise “tailoring” of the safety devices’ deployment to actual accident circumstances.
• Battery Safety Terminal – in case of a severe accident impact, breaks the high-current connection between the battery and starter cable. This helps prevent a possible short circuit in the electrical system.
• Automatic fuel-pump shutoff upon severe accident impact. In addition, the doors are automatically unlocked; the interior lighting and 4-way hazard flashers are switched on. Thus even after an accident, BMW’s safety strategy is still at work.
• Coded Driveaway Protection – BMW’s rolling-code engine immobilizer.
• Central locking system with double-lock feature. When the vehicle is locked from the outside, the double-lock feature prevents individual door-lock buttons from being pulled up; thus even if a thief has broken into the car, it isn’t possible to open the doors.
• Alarm system with interior motion detector – standard on the 5 Series.
• BMW Assist – BMW’s comprehensive system of customer services and in-car telematics is standard on all 5 Series models. Includes a 1-year subscription to BMW Assist services, after which the customer pays an annual subscription fee.

Options:
possibilities new and familiar
Changes to the 5 Series array of Packages and stand-alone options are significant but not extensive. Highlights include deletion of Active Steering from the rear-wheel-drive models’ Sport Packages (it remains a stand-alone option); differently composed Sport Packages for the new all-wheel-drive models; Xenon Adaptive headlights now optional on just two models (they’re now standard on all 530s); and performance run-flat tires as stand-alone options for the all-wheel-drive models.

Packages:
Premium Package. Combines luxury and convenience features:
For all models –
• Leather upholstery
• BMW Universal Transceiver, a 3-function remote for garage doors and other external devices
• Auto-dimming interior and exterior mirrors, now including a power-fold feature
Additionally for 525i and 525xi models –
• 4-way power lumbar support for the front seats, which is standard in the 530s.
Additionally for 530xi Sports Wagon –
• Power tailgate. Released from the interior or exterior switch or the remote, the tailgate opens electrohydraulically. Actual opening height is programmable via the iDrive system, in four steps from a minimum of essentially horizontal to the full 73 in. Closing is from the exterior button. The cargo cover also rises and lowers electrically as the tailgate is opened or closed.
Sport Package. Comes in essentially two forms, one for rear- and one for all-wheel-drive models:
Rear-wheel-drive models –
• Active Roll Stabilization, which dramatically reduces body roll in corners and curves
• Sport suspension calibration
• Sport wheels and tires:
525i Sedan – 17 x 8.0 wheels, 245/45R-17 W-rated run-flat performance tires
530i Sedan – 18 x 8.0 wheels, 245/40R-18 W-rated run-flat performance tires 4
• High-gloss Shadowline exterior trim – all-black around the side windows replaces the standard black-plus-chrome window framing
• 12-way power front sport seats, in place of the standard 10-way power seats
All-wheel-drive models –
• Includes only the exterior and interior features
• No sport suspension or Active Roll Stabilization
• For all-weather attributes, retains standard wheels and tires. Wheels described for 525i and 530i Sedans are available on 525xi Sedan, 530xi Sedan and 530xi Sports Wagon as stand-alone options in combination with the Sport Package.

Cold Weather Package. Combines weather- and versatility-oriented features:
For all models –
• Heated front seats, with variable heating balance via iDrive
• Heated steering wheel
• Headlight cleaning system, with retracting high-intensity liquid jets.
For 530xi Sports Wagon only –
• Ski bag.
Premium Sound Package. Combines BMW’s legendary Logic 7 sound system with a 6-disc CD changer.
STEPTRONIC automatic transmission – 6-speed, like all 5 Series transmissions.
Sequential Manual Gearbox (SMG) – 530i Sedan only; requires the Sport Package.
Active Cruise Control. Employing a radar sensor unit at the front of the vehicle, ACC senses the speed of vehicles traveling ahead, adjusts the BMW driver’s speed to maintain following distance, and offers the driver additional control choices over the standard cruise control.
Active Steering. Exclusive to BMW in the U.S.; offers unique benefits:
• Widely variable steering ratio; steering-wheel movements for parking maneuvers, U-turns and sharp corners are greatly reduced for amazing agility. With increasing vehicle speed, the steering becomes “slower,” favoring stability over agility.
• Vehicle stabilization; in critical situations, can intervene to preserve stability. For example, if the driver applies the brakes while driving on a surface with uneven traction (one side of the road slick, the other grippy), Active Steering can recognize incipient instability and steer against it.
• Not available on xi models
Park Distance Control employs ultrasonic sensors in the front and rear bumpers to detect obstacles that may not be visible to the driver, and emits an acoustic warning. Includes a vehicle diagram in the iDrive display, which graphically depicts obstacles’ locations.
Xenon Adaptive headlights with auto-leveling. Stronger, daylight-like illumination; headlights “steer” to enhance the driver’s view around curves and corners. Optional on 525i/xi models, standard on 530i/xi models.
Leather upholstery – though included in the Premium Package, also available as a stand-alone option.
Maple Anthracite wood interior trim. With its gray color and “striped” grain, this is a distinctive and contemporary alternative to the standard (and also elegant) Dark Poplar.
20-way front Comfort seats. In addition to the standard seats’ 10-way power adjustments, the 20-way power adjustments of these remarkable and comprehensive luxury seats include –
• Thigh support
• Angle of articulated upper backrest section, independently from overall backrest angle
• Backrest width (the backrests’ side bolsters spread or narrow to accommodate the occupants’ back and shoulders)
• 4-way power lumbar support, which is standard in the 530 models.
Split folding rear seats and ski bag for the Sedans.
Heated rear seats, available for all models in combination with the Cold Weather Package.
BMW On-board Navigation System. The standard iDrive system has a 6.5-in. control display (color monitor) at dash center and a turn-and-push controller between the front seats. This option includes an 8.5-in., higher-resolution control display plus:
• GPS Navigation with DVD database
• Voice Command activation of features
• Controller with Force Feedback (adds tactile feedback to controller movements).
Head-up Display – displays important driving-related information on a 6 x 3-in. field in the windshield, just below the driver’s normal line of sight to the road ahead:
• Check Control and On-board Computer warnings, prioritized according to their urgency, such as vehicle defects, engine-oil level, low windshield-washer fluid
• Navigation instructions
• Cruise-control set speed (standard or Active Cruise Control)
• Current vehicle speed.
Sirius Satellite Radio. This appealing path to entertainment, news and information channels is now available as a factory option. A subscription fee is required for Sirius service.
Power rear-window and manual rear side-window sunshades. For the Sedans, the option includes both; for the Sports Wagon, only the side-window shades. The power rear-window shade is controlled from a console switch; the side-window shades are easily raised or lowered by rear-seat passengers.

Performance with a conscience
BMW strives to produce its motor vehicles and other products with the utmost attention to environmental compatibility and protection. Integrated into the design and development of BMW automobiles are such criteria as resource efficiency and emission control in production; environmentally responsible selection of materials; recyclability during production and within the vehicle; elimination of CFCs and hazardous materials in production; and continuing research into environmentally friendly automotive power sources. Tangible results of these efforts include the recycling of bumper cladding into other vehicle components; water-based paint color coats and powder clear coats; near-future availability of hydrogen-powered models; and various design and engineering elements that help make BMWs easier to dismantle at the end of their service life.

Source - BMW Press Club