BMW X5 2000 E53 Xenon Lights Instalation Instruction Manual

K
J K1
K2
K3A
ECE

2-43
F 53 0062 EVA
I3 I2 I1
IH F G
DE C2 C1 B1 B2

2.5 To install the xenon wiring harness (ECE cars only)
The xenon wiring harness is to be secured using cable ties.
Ensure that cables and other lines are not kinked or damaged when they are being installed in the car and that
they do not impair the freedom of movement of other components.
If the specified pins or chambers are already in use, bridges, double crimps or parallel end stops are to be
used.
Fold out folded page 2-77.
A
Overview of connection points
Branch A(X991, 26-pin plug, Bordeaux) is to be connected to the control module for the automatic headlight
adjustment control system on the module holder behind the glove box.
Branch B1(triple joint connector X10466*) is to be fitted in the connector box behind the glove box.
Branch B2(white/red/yellow cable) is to be connected to the K-BUS terminal connector (X10116) behind the glove
box.
Branch C1(triple joint connector X1608*) is to be fitted in the connector box behind the glove box.
Branch C2(brown/black cable) is to be connected to the terminal 31 connector (X596) behind the glove box.
Branch D(yellow/red cable) is to be connected to slot 27 in the light module (X10117, 54-pin, black) on the A pillar
on the passenger side.
Branch E(blue/red cable) is to be connected to the blue/red cable from pin 25 on the light module (X10117,
54-pin, black) using a double mini connector.
Branch Fis to be placed next to the light module on the A pillar on the passenger side.
Eight cables must be disconnected from the light module (X10117, 54-pin, black) and fitted with new contacts.
With casing X1B* (branch G), these then provide the connector for branch F(see section 2.5-D).
The rubber grommet His used to seal the cable passage on the floor of the boot.
Cable I1, grey/white cable, is to be connected to slot 2 of branch I(X1451, 6-pin, black), cable I2, grey/brown
cable, to slot 3 and cable I3, grey/green cable, to slot 6. Any cables in the car for the level sensor are to be
repinned (see section 2.5-F). Branch Iis then to be connected to the level sensor at the rear right.
Branch J(yellow/white cable) is to be connected to slot 18 of the ABS/DSC control module in the front left of the
engine compartment in cars with an optional equipment wiring harness up to level 2. In cars with an optional
equipment wiring harness above level 2, there is a yellow/white cable in the boot at the rear left on the 6-pin plug
X1310S on slot 2, which comes from the ABS/DSC control module, slot 18. Connect branch J(yellow/white cable)
to this cable using a double mini connector.
Cable K1, black/white cable, is to be connected to slot 2 of branch K(X10275, 6-pin, black), cable K2, black/grey
cable, to slot 3 and cable K3, black/green cable, to slot 6. Any cables in the car for the air suspension are to be
repinned (see section 2.5-F). Branch Kis then to be connected to the level sensor at the front right.
B
Connect the control module for the automatic headlight adjustment control system (1) to the module holder behind
the glove box. Connect branch A(X991, 26-pin plug, Bordeaux) to the control module for the automatic headlight
adjustment control system (1) and secure it. The xenon wiring harness goes to the right and splits near the A pillar.
Branches B1to I3go downwards along the vehicle wiring harness, branches B1to C2then go to the
connector box (2). Branches Jto K3go upwards along the vehicle wiring harness.
C
Release the connector box (2) and swing it forwards.
Unclip the K bus multiple connector (X10116, white/red/yellow cables) (3) and terminal 31 multiple connector
(X596, brown/black cables) (4).
If there are any unoccupied slots in the multiple connectors X10116 (3) and X596 (4), connect branches B2,
white/red/yellow cable, and C2, brown/black cable, to the corresponding cable colours.
The procedure if all the slots are occupied is described for multiple connector X10116 (3). If necessary
proceed accordingly for multiple connector X596 (4).
Disconnect a white/red/yellow cable from multiple connector X10116 (3) and connect it to the triple connector
X10466* (B1). Connect branch B2, white/red/yellow cable, to the now unoccupied slot on multiple connector
X10116 (3).
Clip multiple connectors X10116 (3), X10466* (B1), X596 (4) and X1608* (C1) into the connector box (2) and mount
the connector box (2) on the module holder.
EN/2-49

D
Disconnect the 54-pin black plug X10117 (5) from the light module (6) on the A pillar on the passenger side and
take the plug strip off the casing. Lay branches Dand E, yellow/red and blue/red cables, to there. Connect branch
D, yellow/red cable, to slot 27 of the 54-pin plug X10117 (5).
Connect branch E, blue/red cable, to the blue/red cable from slot 25 of the 54-pin plug X10117 (5) using a double
mini connector from the parts kit (7).
Ensure that the casing and plug strip can be assembled and connected to the light module (6) after the mini
connector (7) has been connected.
Disconnect the following cables from the plug strips of plug X10117 (5), fit the contact parts to them supplied in
the parts kit and connect them to the 10-pin casing (G).
Two yellow/brown and two blue/brown cables are to be disconnected but must not be mixed up. Keep to the
order described to avoid confusion.
First disconnect the following four cables:
Slot 2, blue/red cable;
Slot 3, blue/brown cable;
Slot 4, yellow/red cable;
Slot 5, yellow/brown cable.
Remove the contact parts from these cables, strip the cables and fit the contact parts supplied in the parts kit to
them.
Connect the cables as follows to the black 10-pin plug X1B* (G) supplied with the kit:
Connect the blue/red cable to slot 1 of the black 10-pin plug X1B* (G).
Connect the blue/brown cable to slot 2 of the black 10-pin plug X1B* (G).
Connect the yellow/red cable to slot 3 of the black 10-pin plug X1B* (G)
Connect the yellow/brown cable to slot 4 of the black 10-pin plug X1B* (G)
Now disconnect the following four cables:
Slot 20, blue/black cable;
Slot 21, blue/brown cable;
Slot 22, yellow/black cable;
Slot 23, yellow/brown cable.
Remove the contact parts from these cables, strip the cables and fit the contact parts supplied in the parts kit to
them.
Connect the cables as follows to the black 10-pin plug X1B* (G)supplied with the kit:
Connect the blue/black cable to slot 7 of the black 10-pin plug X1B* (G).
Connect the blue/brown cable to slot 8 of the black 10-pin plug X1B* (G).
Connect the yellow/black cable to slot 9 of the black 10-pin plug X1B* (G)
Connect the yellow/brown cable to slot 10 of the black 10-pin plug X1B* (G)
Connect the 10-pin black plug X1B* (G) to branch Fof the xenon wiring harness and stow the plug connector so
that it does not interfere with any other components.
Assemble the 54-pin plug X10117 (5), connect it to the light module (6) and secure it.
Branches I1to I3go further back along the vehicle wiring harness towards the rear.
E
In cars with a vehicle wiring harness above level 2 (see section 1), branch J(yellow/white cable) on the xenon
wiring harness goes parallel to branches I1to I3into the boot.
Lay branches I1to I3(grey/white, grey/brown and grey/green cables) along the right-hand sill wiring harness to
the rear, along the vehicle wiring harness behind the right-hand boot trim and then along the vehicle wiring
harness to the floor of the boot.
Remove the 20 mm sealing stopper from the floor of the boot (the hole in Figure Eis already sealed with the
grommet (H)), deburr the hole and treat it with the normal BMW anti-corrosion coatings.
Place grommet Hon cables I1to I3, grey/white, grey/brown and grey/green cables, and thread cables I1to I3
through the holes to the underside of the car.
The rear axle is beneath the hole.
2-50/EN

F
Lay branches I1to I3(grey/white, grey/brown and grey/green cables) forwards a little on the rear axle, secure them
to the cable holder (8) and lay them to the level sensor (9).
Only for cars without a level control system:
Connect cables I1to I3on the xenon wiring harness as follows:
Connect branch I1, grey/white cable, to slot 2 of the black 6-pin plug X1451 (I).
Connect branch I2, grey/brown cable, to slot 3 of the black 6-pin plug X1451 (I).
Connect branch I3, grey/green cable, to slot 6 of the black 6-pin plug X1451 (I).
Seal slots 1, 4 and 5 using the supplied blind grommets.
Only for cars with a level control system:
Cars with a level control system already have a branch of the vehicle wiring harness to the level sensor at the
rear right and a black 6-pin plug X1451.
Disconnect the three cables in the car (yellow/brown, yellow/grey and yellow/white or yellow/black) and connect
them as follows to the black 6-pin plug X1451 (I) supplied with the parts kit:
On cars with air suspension on one axle:
Connect the yellow/black cable to slot 1 of the black 6-pin plug X1451 (I).
Connect the yellow/brown cable to slot 4 of the black 6-pin plug X1451 (I).
Connect the yellow/grey cable to slot 5 of the black 6-pin plug X1451 (I).
On cars with air suspension on both axles:
Connect the yellow/brown cable to slot 1 of the black 6-pin plug X1451 (I).
Connect the yellow/grey cable to slot 4 of the black 6-pin plug X1451 (I).
Connect the yellow/white cable to slot 5 of the black 6-pin plug X1451 (I).
Connect cables I1to I3on the xenon wiring harness as follows:
Connect branch I1, grey/white cable, to slot 2 of the black 6-pin plug X1451 (I).
Connect branch I2, grey/brown cable, to slot 3 of the black 6-pin plug X1451 (I).
Connect branch I3, grey/green cable, to slot 6 of the black 6-pin plug X1451 (I).
All cars:
Connect the black 6-pin plug X1451 (I) to the level sensor (9).
Seal the hole in the floor of the boot with the grommet (H).
Ensure that the grommet (H) is fitted so that the car is watertight and that the cables do not interfere with any
other components.
G
Only for cars with an optional equipment wiring harness above level 2 (see section 1):
Lay branch J, yellow/white cable, parallel to branches I1to I3(see Figure E) into the boot. Lay branch Jon the
wiring harness along the battery positive distributor, continue behind the boot trim (10) to the 6-pin plug X1310S
(11). Cut branch J, yellow/white cable, to size and connect it to the yellow/white cable from slot 2 of the 6-pin plug
X1310S (11) using the double mini connector supplied in the parts kit (see magnified view).
Drill two holes in the boot trim (10) and secure branch Jto them using cable ties (12) (see magnified view).
Ensure that the spare wheel cannot chafe on branch J (yellow/white cable).
H, I
Only for cars with an optional equipment wiring harness up to level 2 (see section 1):
Lay branch J, yellow/white cable, along the vehicle wiring harness behind the module carrier in the passenger side
footwell to the left-hand side of the car, through the additional passage hole in the front bulkhead grommet (13)
and the grommet (14) into the engine compartment and then along the vehicle wiring harness on the inside wing
to the 42-pin blue plug X1170 (15) on the ABS/DSC control module.
The left front bulkhead grommet (13) does not have an additional passage hole for retrofit wiring harnesses in
the first cars in the series. In this case the cable Jis to be laid along vehicle wiring harness through the front
bulkhead grommet (13).
EN/2-51

Disconnect the 42-pin blue plug X1170 (15) from the ABS/DSC control module, release the plug strip, remove the
blind stopper from slot 18 and connect branch J, yellow/white cable, to slot 18.
Engage the plug strip, connect the 42-pin blue plug X1170 (15) to the ABS/DSC control module and secure it.
J
Lay branches K1to K3, black/white, black/grey and black/green cables, through the additional passage hole in the
right front bulkhead grommet near the electrics box and then through the grommet (16) into the engine compart-
ment. Lay branches K1to K3along the vehicle wiring harness on the inside wing towards the front and to the
engine near the washer water tank.
The right front bulkhead grommet does not have an additional passage hole for retrofit wiring harnesses in
the first cars in the series. In this case the cables K1to K3are to be laid along vehicle wiring harness through the
front bulkhead grommet.
K
Lay branches K1to K3parallel to the cables for the ABS sensor into the wheel arch and connect them to the
black 6-pin plug X10275 (K) as follows:
Cars without air suspension on both axles only:
Connect branch K1, black/white cable, to slot 2 of the black 6-pin plug X10275 (K).
Connect branch K2, black/white cable, to slot 3 of the black 6-pin plug X10275 (K).
Connect branch K3, black/white cable, to slot 6 of the black 6-pin plug X10275 (K).
Seal slots 1, 4 and 5 with the blind grommets supplied.
Cars with air suspension on both axles only:
Two black/white and two black/grey cables are used. it is therefore essential to keep to the order described to
avoid confusion.
There is already a black 6-pin plug X10275 in the car. Disconnect the three cables (black/brown, black/grey and
black/white) from these plugs and connect them to the black 6-pin plug X10275 (K) supplied in the parts kit as
follows:
Connect the black/brown cable for the air suspension to slot 1 of the black 6-pin plug X10275 (K).
Connect the black/grey cable for the air suspension to slot 4 of the black 6-pin plug X10275 (K).
Connect the black/white cable for the air suspension to slot 5 of the black 6-pin plug X10275 (K).
Connect the cables on the xenon wiring harness as follows:
Connect branch K1, black/white cable, to slot 2 of the black 6-pin plug X10275 (K).
Connect branch K2, black/white cable, to slot 3 of the black 6-pin plug X10275 (K).
Connect branch K3, black/white cable, to slot 6 of the black 6-pin plug X10275 (K).
All cars:
Connect the black 6-pin plug X10275 (K) to the level sensor at the front right (17) and secure the wiring harness to
the hole in the axle with a cable tie (18).
Check again that the entire xenon wiring harness has been installed in such a way that none of the cables
are kinked or damaged and that it has been secured with the cable ties so that it does not interfere with any other
components.
2-52/EN

15J
I
B1-C2
D-I3
2
1
A
J-K3B
A B1-C2 D,E
F, G K1-K3
I1-I3
H
J
A
17
18
K1-K3
K
K
16
K1-K3
J
F 53 0063 EVA
F 53 0073 EVA
F 53 0072 EVAF 53 0071 EVA
F 53 0064 EVA
ECE

2-77
13
14
J
H10
12
J
J
11
11
J
1212
10
G
2
3
4
B1C1
B2
C2C
6
7
5
F, G
D
I1-I3
E
D
E I1-I3
E
8
9
I
H
I1-I3
F
F 53 0070 EVAF 53 0090 EVA
F 53 0068 EVA
F 53 0067 EVA
F 53 0066 EVAF 53 0065 EVA
F 53 0054 EVA

EN/2-81
2.6 Connection overview of the xenon wiring harness (ECE cars only)
Fold out folded page 2-95
Item Description Cable colour Connection location in the car Abbreviation /
Slot
A26-pin plug (Bordeaux) - Con. mod. for autom. headlight adjust. cont. sys. X991
B1Triple joint connector - Connector box behind the glove box X10466*
B2Joint connector contact white/red/yellow K-bus connector behind the glove box X10116
C1Triple joint connector - Connector box behind the glove box X1608*
C2Joint connector contact brown/black Terminal 31 connector behind the glove box X596
DBlade terminal contact yellow/red 54-pin plug on light module on passenger side X10117/27
EBlade terminal contact blue/red 54-pin plug on light module on passenger side X10117/25**
FCable grommet - Cable passage to boot -
G6-pin plug (black) - Level sensor at rear right X1451
G1Blade terminal contact grey/white Level sensor at rear right X1451/2
G2Blade terminal contact grey/brown Level sensor at rear right X1451/3
G3Blade terminal contact grey/green Level sensor at rear right X1451/6
H4-pin plug (natural) - Servo motor for left headlight X1034
H1Blade terminal contact yellow/red Servo motor for left headlight X1034/1
H2Blade terminal contact yellow/brown Servo motor for left headlight X1034/2
H3Blade terminal contact blue/red Servo motor for left headlight X1034/3
H4Blade terminal contact blue/brown Servo motor for left headlight X1034/4
IBlade terminal contact yellow/white
ABS/DSC cont. mod. in the engine compart., front leftX1170/18***
J6-pin plug (black) - Level sensor at front right X10275
J1Blade terminal contact black/white Level sensor at front right X10275/2
J2Blade terminal contact black/grey Level sensor at front right X10275/3
J3Blade terminal contact black/grey Level sensor at front right X10275/6
K4-pin plug (natural) - Servo motor for right headlight X1035
K1Blade terminal contact yellow/black Servo motor for right headlight X1035/1
K2Blade terminal contact yellow/brown Servo motor for right headlight X1035/2
K3Blade terminal contact blue/black Servo motor for right headlight X1035/3
K4Blade terminal contact blue/brown Servo motor for right headlight X1035/4

Branch E(marked "**") is to be connected to the cable in the car using a double connector.
Branch I(marked "***") is to be connected to plug X1310S at the rear left of the boot on cars with optional
equipment wiring harness from level 2. See section 2.7-G.
The components marked ”*” are only used for this retrofit kit, all other components refer to the application of
the BMW dealer organisation.
2-82/EN