ECU BMW X5 2000 E53 Xenon Lights Instalation Instruction Manual

Fold out folded page 2-33.
All lock nuts are to be replaced. All tightening torque values are to be taken from the current repair
instructions and must be observed at all times.
2.2 To install the level sensor at the front right
Cars with an air suspension front axle already have a level sensor. This is to be replaced with the level
sensor supplied with the parts kit.
A
Only for cars without an air suspension front axle.
Mounting points for the level sensor at the front right:
The holder with the fitted level sensor is to be installed using the mounting screw (1) on the control arm (3).
The hole (2) is used as a locking device
The angle joint is mounted on the control arm (3).
B
Only for cars without an air suspension front axle.
Install the level sensor (4) on the holder (6) using two Allen bolts, M5 x 10 (5).
See the position of the locking device (7) and the threaded sleeve (see magnified view).
C
Only for cars without an air suspension front axle.
Remove the nut SW16 mm from the mounting screw (1) on the control arm (3) and pull out the mounting screw (1).
Position the holder (6) with the level sensor (4) and secure the control arm (3) with the mounting screw (1) and the
lock nut SW 16 mm supplied in the parts kit.
Install the angle joint (8) on the control arm (3) and secure it with a nut SW10 mm.
Connect the angle joint (8) to the lever on the level sensor (4) and secure it with a nut SW10 mm (9).
Only for cars with an air suspension front axle.
Undo the nut SW10 mm (9) and release the angle joint (8). remove the level sensor (4) in the car (see Figure B)
and replace it with the one supplied in the parts kit.
2.3 To install the level sensor at the rear right
Only for cars without a level control system.
D
Mounting points for the level sensor at the rear right:
The holder with the fitted level sensor and the threaded plate is to be installed on the holes (10). Fit the clip
on the holder (11) on the rear axle swinging arm and secure the control rod.
E
Install the level sensor (12) on the holder (14) using two Allen bolts, M5 x 10 (13).
See the position of the threaded sleeve (see magnified view).
F
Fit the threaded plate (15) into the holes (10) in the frame from the rear.
G
Fit the holder (14) wit the level sensor (12) on to the thread and the journal of the threaded plate and secure
it with a lock nut SW 10 mm (16).
Place the clip (17) on the holder (11) for the rear axle swinging arm.
Connect the lever on the level sensor (12) to the holder (11) for the rear axle swinging arm using the control rod
(18). Secure the control rod (18) with the lock nuts SW 10 mm (19 and 20).
EN/2-7

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

2.7 To install the xenon wiring harness (US 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 2-129
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.
The rubber grommet (F) is used to seal the cable passage on the floor of the boot.
Cable G1, grey/white cable, is to be connected to slot 2 of branch G(X1451, 6-pin, black), cable G2, grey/brown
cable, to slot 3 and cable G3, grey/green cable, to slot 6. Any cables in the car for the level sensor are to be
repinned (see section 2.7-F). Branch Gis then to be connected to the level sensor at the rear right.
Cable H1, yellow/red cable, is to be connected to slot 1 of branch H(X1034, 4-pin, natural), cable H2,
yellow/brown cable, to slot 2, cable H3, blue/red cable, to slot 3 and cable H4, blue/brown cable, to slot 4. Branch
His to be connected to the servo motor on the left Xenon headlight.
Branch I(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 I(yellow/white cable)
to this cable using a double mini connector.
Cable J1, black/white cable, is to be connected to slot 2 of branch J (X10275, 6-pin, black), cable J2, black/grey
cable, to slot 3 and cable J3, black/green cable, to slot 6. Any cables in the car for the air suspension are to be
repinned (see section 2.7-F). Branch Jis then to be connected to the level sensor at the front right.
Cable K1, yellow/black cable, is to be connected to slot 1 of branch K (X1035, 4-pin, natural), cable K2,
yellow/brown cable, to slot 2, cable K3, blue/black cable, to slot 3 and cable K4, blue/brown cable, to slot 4.
Branch Kis to be connected to the servo motor on the right Xenon headlight.
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 G3go downwards along the vehicle wiring harness, branches B1to C2then go to the
connector box (2).
Branches Hto K4go upwards along the vehicle wiring harness.
C
Release the connector box (2) and swing it forwards.
Unclip the Kbus 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).
EN/2-101

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.
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.
Assemble the black 54-pin plug (5), connect it to the light module (6) and secure it.
Branches G1to G3go 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 I(yellow/white cable) on the xenon
wiring harness goes parallel to branches G1to G3into the boot.
Lay branches G1to G3(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 E is already sealed with the
grommet (F)), deburr the hole and treat it with the normal BMW anti-corrosion coatings.
Place grommet Fon cables G1to G3, grey/white, grey/brown and grey/green cables, and thread cables G1to G3
through the holes to the underside of the car.
The rear axle is beneath the hole.
F
Lay branches G1to G3(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 G1to G3on the xenon wiring harness as follows:
Connect branch G1, grey/white cable, to slot 2 of the black 6-pin plug X1451 (G).
Connect branch G2, grey/brown cable, to slot 3 of the black 6-pin plug X1451 (G).
Connect branch G3, grey/green cable, to slot 6 of the black 6-pin plug X1451 (G).
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 (G) 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 (G).
Connect the yellow/brown cable to slot 4 of the black 6-pin plug X1451 (G).
Connect the yellow/grey cable to slot 5 of the black 6-pin plug X1451 (G).
On cars with air suspension on both axles:
Connect the yellow/brown cable to slot 1 of the black 6-pin plug X1451 (G).
Connect the yellow/grey cable to slot 4 of the black 6-pin plug X1451 (G).
Connect the yellow/white cable to slot 5 of the black 6-pin plug X1451 (G).
2-102/EN

Connect cables G1to G3on the xenon wiring harness as follows:
Connect branch G1, grey/white cable, to slot 2 of the black 6-pin plug X1451 (G).
Connect branch G2, grey/brown cable, to slot 3 of the black 6-pin plug X1451 (G).
Connect branch G3, grey/green cable, to slot 6 of the black 6-pin plug X1451 (G).
All cars:
Connect the black 6-pin plug X1451 (G) to the level sensor.
Seal the hole in the floor of the boot with the grommet (F).
Ensure that the grommet (F) 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 I, yellow/white cable, parallel to branches G1to G3(see Figure E) into the boot. Lay branch Ion the
wiring harness along the battery positive distributor, continue behind the boot trim (10) to the 6-pin plug X1310S
(11). Cut branch I, 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 Ito them using cable ties (12) (see magnified view).
Ensure that the spare wheel cannot chafe on branch I(yellow/white cable).
H, I
Figures H and I shows the cable positions for cars with an optional equipment wiring harness up to level 2
(see section 1). In cars with an optional equipment wiring harness above level 2, branch I, yellow/white cable, is to
be connected to the 6-pin plug X1310S at the rear left of the boot (see Figure G).
Lay branches H1to H4, yellow/red, yellow/brown, blue/red and blue/brown cables, and branch I, yellow/white
cable(branch Ionly on cars with an optional equipment wiring harness up to level 2), along the vehicle wiring
harness behind the module holder in the passenger footwell to the left-hand side of the car, through the additional
passage hole in the front bulkhead grommet (13) and through the grommet (14) into the engine compartment.
Lay the cables along the vehicle wiring harness on the inside wing to near the left headlight.
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 cables H1to H4and I(only on cars with an optional equipment wiring
harness up to level 2) are to be laid along vehicle wiring harness through the front bulkhead grommet (13).
Connect branches H1to H4to the casing H(X1034, 4-pin. natural) as follows:
Connect branch H1, yellow/red cable, to slot 1 of the 4-pin plug X1034 (H).
Connect branch H2, yellow/brown cable, to slot 2 of the 4-pin plug X1034 (H).
Connect branch H3, blue/red cable, to slot 3 of the 4-pin plug X1034 (H).
Connect branch H4, blue/brown cable, to slot 4 of the 4-pin plug X1034 (H).
After the xenon headlight has been installed, the 4-pin plug X1034 (H) is to be connected to the servo motor for
the headlight.
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 I, 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 J1to J3, black/white, black/grey and black/green cables, and cables K1to K4, yellow/black,
yellow/brown, blue/black and blue/brown 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 compartment. Lay branches J1
to J3and K1to K4along the vehicle wiring harness on the inside wing towards the front.
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 J1to J3and K1to K4are to be laid along vehicle wiring
harness through the front bulkhead grommet.
Lay branches J1to J3to the engine near the washer water tank.
EN/2-103

Lay branches K1to K4further along the vehicle wiring harness to the plugs for the right headlight and connect
them to the supplied casing K(X1034, 4-pin natural) as follows:
Connect branch K1, yellow/black cable, to slot 1 of the 4-pin plug X1035 (K).
Connect branch K2, yellow/brown cable, to slot 2 of the 4-pin plug X1035 (K).
Connect branch K3, blue/black cable, to slot 3 of the 4-pin plug X1035 (K).
Connect branch K4, blue/brown cable, to slot 4 of the 4-pin plug X1035 (K).
After the xenon headlight has been installed, the 4-pin plug X1035 (K) is to be connected to the servo motor for
the headlight.
K
Lay branches J1to J3parallel to the cables for the ABS sensor into the wheel arch and connect them to the black
6-pin plug X10275 (J) as follows:
Cars without air suspension on both axles only:
Connect branch J1, black/white cable, to slot 2 of the black 6-pin plug X10275 (J).
Connect branch J2, black/white cable, to slot 3 of the black 6-pin plug X10275 (J).
Connect branch J3, black/white cable, to slot 6 of the black 6-pin plug X10275 (J).
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 (J) 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 (J).
Connect the black/grey cable for the air suspension to slot 4 of the black 6-pin plug X10275 (J).
Connect the black/white cable for the air suspension to slot 5 of the black 6-pin plug X10275 (J).
Connect the cables on the xenon wiring harness as follows:
Connect branch J1, black/white cable, to slot 2 of the black 6-pin plug X10275 (J).
Connect branch J2, black/white cable, to slot 3 of the black 6-pin plug X10275 (J).
Connect branch J3, black/white cable, to slot 6 of the black 6-pin plug X10275 (J).
All cars:
Connect the black 6-pin plug X10275 (J) 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.
2-104/EN

Fold out folded page 2-147.
2.8 To remove the manual headlight adjustment control system (ECE cars only)
A
Remove the fresh air grille (1).
Remove the light control (2) with the manual headlight adjustment control system (3) and replace it with the light
control in the parts kit.
To install the parts proceed in reverse order.
2.9 To install the xenon headlights
The procedure is shown for the right-hand side of the car, proceed accordingly on the left-hand side.
B
Take the holder with the integral control module (4) off the xenon headlight (5).
The control module (4) is connected to the headlight by a cable (6).
Position the holder and integral control module (4) in the car with the screws (7), position. Align and secure the
xenon headlight (5).
Connect all the plug connectors.
On US cars also connect the 4-pin plugs X1034 and X1035 (branches Hand Kon the xenon wiring harness)
to the servo motors.
2.10 To affix the warning sticker
C
The procedure is shown for the right-hand side of the car, proceed accordingly on the left-hand side.
Clean the cross traverse (8) and affix the warning sticker (9).
2.11 To assemble the car
Assemble the car by replacing all the parts you removed, but in reverse order.
2.12 Coding
This retrofit system is coding-relevant.
The coding is required to ensure that the retrofit system is fully functional and to rule out the possibility of
malfunctions and faults when it works in conjunction with other electrical systems in the car.
In addition the retrofit system is saved in the central code of the IKE (integrated combination electronics)/
instrument combination.
The coding work is to be completed using the DIS/MoDIC and is performed automatically in the "Retrofit" path
using the latest coding program.
The procedure is user-guided. Refer to the text instructions as you go through the various stages.
Print out the error memory and conduct a function test.
2.13 Function test
When you switch on the dipped headlights, the headlights must adjust automatically.
Check the function of the automatic headlight adjustment control system by loading the front and rear of the car.
EN/2-133