headlight BMW X5 2000 E53 Xenon Lights Instalation Instruction Manual
[x] Cancel search | Manufacturer: BMW, Model Year: 2000, Model line: X5, Model: BMW X5 2000 E53Pages: 38, PDF Size: 1.18 MB
Page 1 of 38
Xenon-Licht mit automatischer Leuchtweitenregulierung
für BMW X5 (E 53) LHD
Fachkenntnisse sind Voraussetzung.
BMW Parts and Accessories – Installation Instruction
Xenon lights with automatic headlight adjustment control systemfor the BMW X5 (E 53), LHD
Instructions de montage des pièces et des accessoires BMW
Eclairage au xénon avec réglage automatique de la portée des pharespour BMW X5 (E 53) à direction à gauche
BMW Onderdelen en accessoires – Montagehandleiding
Xenon-licht met automatisch instelling van de koplampenvoor BMW X5 (E 53) LHD
BMW Delar och tillbehör – Monteringsanvisning
Xenonljus med automatisk ljusbreddsregleringför BMW X5 (E 53) vänsterstyrd
Ricambi e accessori BMW – Istruzioni di montaggio
Luci allo xeno con regolatore automatico della profondità d'illuminazioneper BMW X5 (E 53) LHD
BMW piezas y accesorios – instrucciones de montaje
Luces de Xenón con regulación automática del alcance de las luces
para BMW X5 (E 53) VVI
Peças e Acessórios BMW – Instruções de Montagem
Luz de xénon com regulação automática do alcance dos faróispara os modelos BMW X5 (E 53) de volante à esquerda
Best.-Nr. 01 29 0 007 010 XI/99 Printed in Germany
Teile und Zubehör - Einbauanleitung
F 53 0054 EVA
Page 3 of 38
EN/1-3
1. Important information
(Only for use within the BMW dealer organisation.)
Installation time approx. 7.5 hours.
The installation times may differ depending on the condition of the car and the equipment in it.
This retrofit system may only be installed with a headlight cleaning system.
All servicing, repair, installation and adjustment work on cars is conducted on your own responsibility.
All work is to be completed using the latest BMW
–Repair instructions,–Circuit diagrams,
–Service manuals,–Work instructions,
–Diagnostics manuals
in a rational sequence using the prescribed tools (special tools) and pursuant to the relevant health and safety
regulations.
Safety notes
An optional equipment wiring harness is used on the E53. This means that if a car is fitted as standard with at
least one of the following pieces of special equipment (SA), the other modules (MD) for the special equipment on
this level will also be integrated in the vehicle wiring harness.
The modules for the special equipment for the lower levels will then also be available.
Example: If a car is fitted with SA 536 (auxiliary heating system), all models on level 3, level 2 and level 1 will be
available.
Level 2
SA 235 (MD AHM) (trailer hitch)
SA 502 (MD SRA)
SA 508 (MD PDC)
SA 609 (MD navigation system)
SA 624 to 629 (US SA 640 (MS car telephone / radio)
Level 3
SA 248 (MD steering wheel heating system)
SA 261 (MD rear airbag)
SA 265 (MD RDC) (tyre pressure control module)
SA 461 (MD backrest heating system in the rear)
SA 496 (MD seat heating system in the rear)
SA 533 (MD rear air conditioning)
SA 536 (MD auxiliary heating system)
Level 4
SA 220 (MS single axle level control)
Level 5
SA 522 (MD automatic headlight adjustment control system / xenon lights)
Safety information
These installation instructions are only valid for LHD cars.
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.
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.
Do not use so-called ”Scotchlock connectors" since they may cause faults in the vehicle's electrical system.
Page 5 of 38
2. Installation
Contents.................................................................................................................................Pa g e
2.1 Preparation ............................................................................................................................. 2-6
2.2 To install the level sensor at the front right .............................................................................. 2-7
2.3 To install the level sensor at the rear right................................................................................ 2-7
2.4 Connection overview of the xenon wiring harness (ECE cars only) .......................................... 2-36
2.5 To install the xenon wiring harness (ECE cars only) ................................................................. 2-49
2.6 Connection overview of the xenon wiring harness (US cars only) ............................................ 2-81
2.7 To install the xenon wiring harness (US cars only) ................................................................... 2-101
2.8 To remove the manual headlight adjustment control system (ECE cars only)........................... 2-133
2.9 To install the xenon headlights ................................................................................................ 2-133
2.10 To affix the warning sticker ...................................................................................................... 2-133
2.11 To assemble the car ................................................................................................................ 2-133
2.12 Coding .................................................................................................................................... 2-133
2.13 Function test ........................................................................................................................... 2-133
2.14 To adjust the xenon headlights ................................................................................................2-134
EN/2-5
Page 6 of 38
2.1 Preparation
Print out the error memory.
Disconnect the battery.
Remove the door sill strips on the right-hand side.
Remove the bottom A pillar trim on the right-hand side.
Remove the glove box.
Remove the footwell trim on the right-hand side.
Remove the air guide in front of the module holder.
Remove the B pillar trims on the right-hand side.
Remove the front passenger seat.
Remove the cable covers in the right-hand sill area.
Remove the backrest side section on the right-hand side and the rear seat bench.
Remove the boot cover.
Remove the spare wheel.
Remove the wheel wrench mounting.
Remove the cover from the electrics box in the engine compartment.
Remove the air filter casing.
Remove the halogen headlights and holders.
Remove the wheels at the front right and rear right.
Only on cars without a standard navigation system (see section 1) or on US cars:
Remove the A pillar trim on the left-and side.
Remove the cover for the pedals and steering column.
2-6/EN
Page 10 of 38
2-36/EN
2.4 Connection overview of the xenon wiring harness (ECE cars only)
Fold out folded page 2-43
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
ECable blue/red 54-pin plug on light module on passenger side X10117/25**
F10-pin plug (black) - Connect to branch G X1S*
G10-pin plug (black) - Connect to branch F X1B*
HCable grommet - Cable passage to boot -
I6-pin plug (black) - Level sensor at rear right X1451
I1Blade terminal contact grey/white Level sensor at rear right X1451/2
I2Blade terminal contact grey/brown Level sensor at rear right X1451/3
I3Blade terminal contact grey/green Level sensor at rear right X1451/6
JBlade terminal contact yellow /white
ABS/DSC cont. mod. in the engine compart., front leftX1170/18***
K6-pin plug (black) - Level sensor at front right X10275
K1Blade terminal contact black/white Level sensor at front right X10275/2
K2Blade terminal contact black/grey Level sensor at front right X10275/3
K3Blade terminal contact black/green Level sensor at front right X10275/6
Branch E(marked "**") is to be connected to the cable in the car using a double connector.
Branch J(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 1). See section 2.5-G.
The components marked ”*” are only used for this retrofit kit, all other components refer to the application
of the BMW dealer organisation.
Eight cables must be disconnected from the light module C (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).
Page 13 of 38
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
Page 19 of 38
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
Page 23 of 38
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
Page 25 of 38
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
Page 26 of 38
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