Several production changes were made to the E65 Body and further changes were introduced beginning with the production of the E66.
There were more changes made to the electronics as well as the body with the Facelifted models 06-08.
Dimensions
Dimensions are the same as Pre-Facelift. It is possible to put facelift body parts and headlights on Pre-Facelift version.
02-08 E65/E66 ground clearance and radius
Bodyshell
The body of the E65 is a light weight design.
The design has essentially been determined by styling, crash performance, comfort, ergonomics and quality.
The E65 panels are made of different steel types and material thickness. These factors together create strong bonding advantages:
• The unladen weight of the vehicle is reduced, thereby lowering energy consumption.
• Improved crash performance resulting in increased passive safety.
• Increased body rigidity resulting in improved directional stability.
• A reduction of vibrations and acoustic noises provides the driver with increased driving comfort.
Through the use of high tensile steel and the use of spot weld bonded joints, it is possible to avoid an excessive body weight increase.
Materials
The choice of materials for the bodyshell is geared towards the design objectives:
• Static Performance (rigidity and strength)
• Dynamic Performance (reduction of vibrational and acoustic disturbances)
• Crash Performance (Improve passive safety)
• Weight Optimization (reducing fuel consumption and improving handling)
Roughly 90% of the sheet panels used in the bodyshell consists of higher-tensile steels.
In comparison, only roughly 30% of higher-tensile steels was used in the E38 while only 5% was used in the E32.
In addition to the benefits of reduced weight and increased strength, the use of higher-tensile sheet panels provides the possibility of a more efficient deployment of materials in the manufacture of the vehicle.
Front End
The front end is joined together from over 100 individual parts by shielded-arc and spot weld bonding.
The vehicle identification number is located on the right front strut tower.
The strut tower provides elongated holes for a further 0.5 degree of camber adjustment.
Front Bumper
The front bumper is made of aluminum.
There are no longer any shock absorbers used in the bumper assembly.
In the complex structure with the bumper trim and the polystyrene foam impact absorber, it can absorb a 15 km/h frontal impact without deformation of the body structure.
Front PAnel (Core Support)
The front panel is made from aluminum for weight reduction and consists of three components bolted together.
The bolted construction makes replacing the radiator and air-conditioning components
an easier task by removing the center section and removing them from the top.
In case of a minor collision the front panel can also be replaced in sections by regular service technicians making it less expensive to repair.
Frame Rails
The frame rails are designed in the profile section as a double hexagon.
This optimal cross sectional geometry offers good exploitation of the available space.
Front axle attachments are integrated in the engine carrier and consists of an extruded part similar to the E39.
The wheel arch has a diagonal support on the front wheel arch liner that uses a technology called “IHPD” (internal high pressure deformation).
The frame rail and wheel house assembly has the advantage of reduced weight and increased rigidity. A similar IHPD section has been fitted in the E46 convertible located in the windshield frame as a rollover protective structure.
Because of their special properties, these profile sections cannot be reworked after a collision. They must therefore be replaced after any deformation.
Joints and Gaps
When removing or replacing body parts it is essential to adjust the gap dimensions and parallelism in compliance with BMW specifications.
Symmetry has top priority for the overall appearance of the joints/gaps on the components. A maximum deviation of +/- 0.5mm to the specified values must be observed here.
