Before it can go into series production, the new edition of the sports sedan must first complete a programme of testing whose breadth and intensity far exceed the stresses and strains of everyday driving. Welcome to Death Valley, in the US state of Nevada. Here, it is not only the automatic climate control system of the new BMW 3 Series Sedan that can expect a taxing work-out. The multi-day heat tests see the cars fried repeatedly in the sun for several hours, then cooled and thoroughly checked over. Everything has to work, there can be no squeaks or creaks – even when the temperature tops 50 degrees Celsius in the shade outside the car and 60 degrees inside, and the interior is then cooled again as quickly as possible. The heat certainly gives the electronics something to think about, but that’s not the whole story: the electromagnetic rays emitted by the hydroelectric plant at the Hoover Dam represent the ultimate test of strength for the functional reliability of the electronic systems on board the new 3 Series. This is why all the car’s functions – from the digital instrument cluster to the tyre pressure indicator – are tested extensively in the shadows of the huge forest of electricity pylons on the banks of Lake Mead. At the same time, another development team is putting engines, transmissions and brakes through their paces. They are even given police protection for their runs up and down the 4,000-metre-high Mount Whitney. While law enforcement secures the test route at the top and bottom of the climb, the testers hustle the prototypes time and again up the snaking roads and back down – accelerating hard and braking suddenly to a standstill with crushing frequency. The bone-dry desert roads of Death Valley and beyond also provide an ideal place to find out how effective the cars’ flaps, doors, bonnets and lids are at keeping out dust. In their test drives around the gambling hot-spot of Las Vegas, the engineers leave nothing to chance.
