BMW 5 SERIES 2003 E39 Model Yar Changes

11
2001 model year changes
The parking light and side marker use the optical wave guide technology. Clear rings
surround the high and low beam reflectors. The rings are illuminated by a light source
module similar to the ones used in the Visual Entry Aid system. Output voltage for the light
source module comes from the parking lamp final stage of the LCM III. There is one light
source module located at the back of the head light housing between the high and low
beam headlights. The side marker for US models also has an additional wave guide con-
ductor for illumination.
Third generation Xenon headlights manufactured by Hella are standard equipment on V-8
powered cars and available as an option on the 6 cylinder models. All xenon equipped
vehicles also use LWR automatic headlight adjustment to maintain the vertical adjustment
of the headlights at any vehicle load. (
Refer to the 1999 Model Update training for details of sys-
tem operation)
Light source module
US version side marker reflector with wave
guide illumination.

12
2001 model year changes
Tail lights
The rear light housings have also been modi-
fied for 2001. No body changes were neces-
sary.
The LED illuminated tail lights provide an excit-
ing fresh look to the part of a 5 Series most dri-
vers on the road are familiar with.
Each tail light housing contains 4 wave guide
assemblies. At either end of the wave guides
is a printed circuit board with 4 LEDs. The
LEDs provide the illumination for the tail light
only. US models use an additional 4 LEDs in
the corner of the housing as a side marker.
On Sport Wagon models, the tail light assem-
bly is two pieces. In this case there continue
to be only two sets of LEDs; one supplying
light for each half of the housing. US models
also have two LEDs for the side marker.
The advantage to using LEDs is the longer life
span as well as lower power consumption.
The function of the LCM III remains unchanged from the previous year with the exception
that because of the LED illuminated tail lights, there is no tail light monitoring function. The
LCM III module has been updated for the new lighting features of the 2001 E39. All
replacement LCM modules will supercede to this version in the parts system and it can be
used on earlier vehicles.
1. Turn Signal
2. Wave Guide Tail light
3. Side Marker
4. Brake light
5. Reversing Light
6. Rear Fog light (Not used for US)
Four wave guides illuminated by 8 LEDs
3
1
5
2
64
Sedan left tail light housing

13
2001 model year changes
E39 IHKR
The 525i/it will be fitted with IHKR as standard
equipment. IHKA will be available as an option
on those vehicles by ordering the Convenience
package: SA 466.
IHKR is a semi-automatically regulated heating
and air-conditioning system. The components
are similar to the IHKR system used in the X5
3.0i.
The E39 IHKR is a single zone system that regulates the temperature of the cabin based
on the occupants desired temperature, selected by a temperature setting dial. Blower con-
trol, air distribution settings and stratification flap are manual.
System Components
The E39 IHKR consists of the following components:
 IHKR control unit with operating controls
 IHKR integrated heater and air conditioning case
 1 Heater core temperature sensor
 Evaporator temperature sensor
 Interior temperature sensor (located in drivers footwell)
 Double cage blower motor and final stage
 1 Water valve (duty cycle controlled)
 Auxiliary water pump
 1 Fresh air/re-circ stepper motor
 Auxiliary fan (DME controlled)
 Refrigerant Pressure Sensor
 Left and right fresh air micro-filters

14
2001 model year changes
E39 IHKR I.P.O.
-+
HEATERCORE
TEMPERATUREHEATER CORE
TEMPERATURE
DME
KL31
KL30
KL15
FAN SPEED
A/C REQUEST
RECIRCULATION
REAR DEFROST
TEMPERATURE
CONTROL
EVAPORATOR
TEMPERATUREWASHER JET HEATER
BLOWER MOTOR OUTPUT STAGE
REAR WINDOW DEFROST RELAYWATER VALVE
FRESH AIR/RECIRC MOTOR
E39
IHKR
REFRIGERANT PRESSURE
0
45
80 72
TEMP
INTERIOR TEMPERATURE
(FOOTWELL)
LCM58G
K-BUS
KOREL
+M
COMPRESSORCONTROLCOMPRESSOR CONTROL
KL 30
KL 15
BMWDISBMW
DISBMWDISB
M
WD
I
S
DSC III
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K-BUS
M
AUXILIARY WATER PUMP
COMPRESSOR
SHUT OFF/ON
SIGNAL

15
2001 model year changes
IHKR control unit with operating controls
The IHKR control unit is incorporated into the control panel. The control panel consists of
three buttons and three rotary dials.
Functional Description:
Air distribution:is carried out using the mechanical rotary dial acting on three
bowden cables.
Blower adjustment:is carried out using the rotary dial potentiometer (22 steps). The
control unit signals the final stage via a variable voltage signal.
Temperature control: The desired interior temperature is set with the rotary dial
potentiometer on the control panel. Temperature regulation is based on the Y-factor.
The inputs used to determine the Y-factor are:
 Position of the temperature control potentiometer dial
 Heater core temperature
 Coolant temperature
 Exterior Temperature
 Interior Temperature
Control of the interior temperature is carried out by the control unit cycling the water
valve to regulate the temperature of the heater core. During heater operation the
auxiliary water pump will be switched on to increase coolant circulation through the
heater core. The service station feature is carried over to the E39 IHKR.
Fresh air/recirculation:Recirculation is requested by an input to the control panel
button or the MFL. The control unit actuates the fresh air/re-circ stepper motor for
control of the flap position. Ram effect air is compensated for.
Air conditioning: :

The request for air conditioning is made by means of a push button.
X611 X610
12 pin 26 pin
X18341
3 pinBlue - vent flaps
Red - defrost flaps
Green - footwell flaps3 cables1. Temperature control potentiometer
2. Air distribution mechanical knob
3. Fan control potentiometer
123
4
5
6
4. Recirculation
5. Air conditioning request
6. Rear window defroster

16
2001 model year changes
The IHKR control module communicates with the DME via the K-Bus/KOMBI/CAN Bus
link to request permission for compressor activation. The control of the compressor
clutch is directly by the IHKA module via a final stage.
 
Rear Window Defroster:The rear window defroster is controlled via a request from
the button on the panel. After switching on for the first time, the rear window is heated
for 10 minutes. Output voltage to the window is provided by the K13 rear defogger
relay. After automatic switch off, if the button is pressed once again the control unit will
pro vide a clocked operation alternating at 40 seconds on and 80 seconds off. If the
vehicle voltage drops below 11.4V during this second heating operation the function is
stopped, however the LED on the button will not be extinguished. If voltage increases
past 12.2V for at least one second, clocked operation will resume. Clocked operation
continues until the button is pressed again or the ignition is cycled.
Washer Jet Heating:The IHKR provides operating current to the washer jet heaters
based on outside temperature. The washer jets are heated below an outside
temperature of 37
oF.
K-Bus Communication:The IHKR control unit is on the vehicle K-bus and receives
and sends information concerning:
 Engine temperature, RPM, KL61, KL50, compressor request, auxiliary fan request,
compressor load (DME)
 Outside temperature KL15 and road speed (KOMBI)
 Diagnosis and coding (DIS/MoDiC)
Ventilation Flap
Stratification flap
Heater Core
Defrost Flap
Evaporator
Outlet, rear footwellOutlet, Rear compartment
Blower
Left side of IHKR case

17
2001 model year changes
IHKA IV
The IHKA system is standard equipment on 530i, 540i/it and M5 models. It is available as
an option for the 525i/it. IHKA has been redesigned for the 2001 E39, it is identified as
IHKA IV. The carry over features from the previous version are:
 Integrated control panel/module.
 Separate temperature control for driver and passenger.
 Air distribution control through the use of 5 “smart” stepper motors and one fast acting
hard wired stepper motor.
 Automatic recirculation control (AUC).
 Recirculation control via MFL.
 “Rest” function for residual heat when engine is not running.
 Service station feature that closes the water valves when stopped to prevent hot coolant
flooding the heater core.
 A/C compressor clutch activation via a final stage control.
 Stratification flap control via a bowden cable.
Please refer to the Climate Control course material ST 054 for a complete functional description of
E39 IHKA
70 0 F 640 F
-+AUTO
A
AUTO
MAX

18
2001 model year changes
E39 IHKA IV I.P.O.
E39 IHKA IV
CONTROL
PANEL/
MODULE
MAX DEFROST
DEFROST VENT A/C COMPRESSOR
FACE VENT RECIRCULATION - AUC
FOOTWELL VENT REAR DEFROST
AUTOMATIC PROGRAM
MAX COOLING/
REST HEATING
FAN SPEED
REQUEST
INDEPENDENT DRIVER
& PASSENGER SIDE
TEMPERATURE CONTROL
HEATER CORE TEMPERATURE SENSORSEVAPORATOR
TEMPERATURE
COMPRESSOR
SHUT OFF/ON
SIGNAL (KO REL)
+ +REAR
WINDOW
DE-FOGGER
RELAY
AUTO
MAX
70 F 76 F
INTERIORAIR
BLOWER
RELAYBLOWER
RELAY
KL31KL 31KL30KL 30
KL15KL 15
M-BUSM-BUS
-FA C EVENTFLAP
-DEFROST
-FOOTWELL
-FRESHAIR/RECIRCULATION
-RAMAIRFLAP
- FACE VENT FLAP
- DEFROST
- FOOTWELL
- FRESH AIR/RECIRCULATION
- RAM AIR FLAP
FIVESTEPPER
MOTORSFIVE STEPPER
MOTORS
FRESHAIRFLAP
STEPPERMOTORFRESH AIR FLAP
STEPPER MOTOR
INTERIOR AIR TEMP
PHOTO TRANSISTOR
DIAGNOSIS AND CODING
6411839142064 118391420
6411839142064 118391420
COMPRESSOR
CONTROLCOMPRESSOR
CONTROL
AUXILIARYWATERPUMPAUXILIARY WATER PUMP
AUCGAS
SENSOR
HEATERAUC GAS
SENSOR
HEATER
K-BUSK-BUS
-Coolanttemp
-
OutsideAirTemp
-
Vehiclespeed
- Coolant temp
- Outside Air Temp
- Vehicle speed-KLR
-
RecircfromMFL
-
Diagnosis
-KLR
- Recirc from MFL
- Diagnosis
LEFT
WATER
VA LV ELEFT
WATER
VA LV ERIGHT
WATER
VA LV ERIGHT
WATER
VA LV E
-+
A
M
WASHER JET HEATING
2-8VOLT
SIGNAL2-8 VOLT
SIGNAL
MM
BLOWERMOTOR
OUTPUTSTAGEBLOWER MOTOR
OUTPUT STAGE
+
BLOWER
BMWDISB
M
WD
I
SBMWDISBMWDIS
DSC III
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K-BUS
DME
SOLAR SENSORSAUC OXIDIZABLE
GAS SENSOR

19
2001 model year changes
Changes made to the E39 IHKA
 New Control Unit (since 9/00).
 Addition of solar sensor (since 9/00).
 New IHKA integrated heater and air conditioning case (since 3/00).
IHKA IV Control Unit
The “REST” button on the control unit has been
replaced with a “MAX” button. Two different functions
are carried out by pushing the MAX button:
 Maximum cooling function
 Residual heat function
Determination of which function will be enabled is
based on switching criteria.
A/C MAX function
(This feature was introduced in the E38 since 9/99)
Maximum cooling performance is automatically activated by pressing the MAX button. An
LED on the button illuminates to indicate that the function is active.
Criteria for operation:
Terminal 15 “on” , MAX button pressed and outside temperature above 60
oF.
The following settings are adjusted or activated:
 Temperature control is canceled and the temperature display indicates 60
o F.
 Both water valves are closed.
 The left and right Y-factors are set to -27.5%.
 The compressor is switched on (LED turns on in the A/C switch).
 The blower setting is set to maximum.
 Recirculation is activated (LED turns on in the re-circ switch).
 Air distribution is set to center vents only.
Operation of the max defrost is overridden by selecting MAX. The operation of the rear win-
dow defogger is not affected.

20
2001 model year changes
REST Function
The REST function continues to operate as usual except that the MAX button has taken the
place of the REST button. Activation criteria continues to be:
 Ignition “OFF” or in KL R.
 “MAX” button pressed.
 Outside temperature below 60
o F.
 Coolant temperature above 80o C.
 Battery voltage above 11.4V.
The REST feature operates as previously.
Diagnostics
The IHKA IV diagnosis has been upgraded to the E46 style diagnostic program.
Solar Sensor
The IHKA IV integrates the solar sensor into the
calculation used to automatically regulate the
interior vehicle temperature. The sensor is
located in the right side defrost outlet.
In the case of a very sunny day, the interior
warms faster than the control unit can compen-
sate for. Similar is true if the weather suddenly
becomes overcast.
The input of the solar sensor in the E39 can
affect the operation of:
 Blower setting
 Air distribution to center vent
Because the E39 IHKA IV is a dual zone system. the solar sensor housing contains two
photo-resistors that measure solar radiation on the left and right halves of the interior.
(Please refer to the Solar Sensor module in the 2000
Systems Diagnosis training course ST 039 for a com-
plete description of the solar sensor operation and
diagnosis)
Solar Sensor
Two photo-resistors
inside of housing