tailgate BMW X5 2002 E53 Workshop Manual

TABLE OF CONTENTS
Subject Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Hood/Front Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Doors/Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Climate Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Cargo Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Drivetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
EHC Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Wheels & Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
STO36 X5

13
Rear Seat Backrest Adjustment
Electric rear seat backrest adjustment is
available on the X5 as optional equipment.
Each backrest can be adjusted individually
up to 20 degrees. the backrest adjustment
option consists of the following:
• Left/Right adjusting motors with gear
drive and seat back hooks - located
behind the seat backs on the shock
towers. The rear seat backs lock into
the “D” shaped hooks on the backrest
adjustment linkage.
• Left/Right adjusting switches - located
in the interior light housing in the head-
liner panel.
• Left/Right adjusting switches - located
in the rear on the left and right sides of
the “D” pillar behind the upper tailgate.
52530013
63530002
52530014

14
System Operation
The seat backs are adjusted from the two different locations as follows:
• The switches in the interior light housing receive operating power through the seat back
relay when the ignition is switched on KL 15. The GM controls the operation of the relay
and the switches provide the ground.
• The switches in the “D” pillar receive KL 30 and allow seat back adjustment whenever
the rear tailgate is opened to gain access to the switches.
• The adjustment motors receive power and ground directly from the switches.
MM
General ModuleBackrest RelayBackrest Adjustment
Switch LeftBackrest Adjustment
Switch Right
Backrest Adjustment
Switch LeftBackrest Adjustment
Switch Right KL30
Motor, Backrest Left Motor Backrest Right

25
Tailgate
The tailgate on the X5 is two sections that
open up and down. The upper section has a
fixed bonded rear glass that incorporates the
rear window wiper and motor assembly. Two
gas strut pistons are used on the upper sec-
tion for opening. An electric actuator is incor-
porated in the upper section with the micro
switch for operation located between the two
license plate lights. The actuator locks into
the lower tailgate section when closed.
A micro-switch positioned in the center console switch
panel is used to open the tail gate from inside the
vehicle.
Operation of the upper tail gate is con-
trolled from the GM which locks the
operation of the gate when the vehicle
speed is over 5 MPH. A dealer installed
class three trailer hitch is available as an
option with a towing capacity of 6000
pounds.
00530015
00530016

26
Tailgate
The lower tailgate section also uses an electric actuator for its operation. The actuator is
positioned in the center of the tailgate and operates two latches though bowden cables.
The latches are positioned on the left and right sides of the tailgate. Two springs are used
to dampen the operation of the lower tailgate section.
Adjustments of the rear tailgate are car-
ried out at the tailgate body latch on the
left and right sides.
51530003
51530004
5153000551530006

27
Tailgate (Emergency Opening)
Both sections of the tailgate incorporate emergency release mechanisms for opening the
tailgate in the event of electrical or component failures.
The upper tailgate release is a plastic pull tab positioned on the right side of the inner trim
cover. Pulling the release tab will mechanically release the upper actuator.
The lower tailgate emergency release is accessed by removing the trim cover on the tail-
gate section. With the gate closed, only the top section will be able to be loosened. The
mechanical release is actuated by inserting a small screwdriver into the opening and press-
ing the latch to the left.
Emergency Release
Emergency Release

36
EHC System Components
Control Module
The Control Module is mounted in the module carrier box in the luggage compartment on
the right side. It contains the processing electronics and final stages for operation of the
EHC system.
The control module receives the follow-
ing inputs for its processing functions:
• KL 30 & 31 (Power/Ground)
• KL 15
• Left & Right Ride Height Sensors
• K Bus for;
- Vehicle speed
- Engine running
- Door/tailgate - open/closed
The control module incorporates two filters (slow/rapid) for processing the input signals
from the ride height sensors. Depending on the operating mode, either the slow or rapid fil-
ter is used to check the need for a regulating sequence.
The slow filter is used during the normal operation mode to prevent normal suspension trav-
el from causing the system to make adjustments.
The rapid filter is used during the pre-run and tailgate (LID) modes to ensure that the sus-
pension is adjusted quickly while the vehicle is being loaded or checked prior to operation.
12530012

41
EHC System Operation
A fully functional EHC system is controlled by one of three different modes of operation.
The operation mode is selected by the control module based on current conditions provid-
ed by the monitored input signals. The main modes of operation are:
• Pre-Run/Post-Run Mode
 Normal Mode
 Tailgate Mode
Two special operating modes are also included in the control module programming.
 New/replacement mode(pre ZCS encoded). This mode provides basic operation.
 Transport Mode - Transport mode is set at the factory and raises the vehicle 30mm to
prevent vehicle damage during transportation. It must be deactivated with the DIS/
MoDiC prior to customer delivery.
Pre-Run/Post-Run Mode
The Pre-Run mode is activated when the vehicle is parked and the control module is in the
sleep mode. Opening a door or the tailgate initiates a system wake up and the control mod-
ule comes on-line.
The control module performs a self-check of the control electronics and sensors. If no fault
is found, the system will check the ride height and institute a rapid regulation if the height
varies by more than 40mm.

42
Normal Operation Mode
Once the rear lid is closed, KL 15 switched ON and the engine started, the system switch-
es into the normal operation mode. In the normal mode, the control module will constantly
monitor the input signals from the ride height sensors and will activate a correction if the
ride height deviates by at least 10mm.
Tailgate Operating Mode
The tailgate operating mode is activated if the gate is opened with KL - 15 On and the
engine running. The difference between this mode and the normal operating mode is the
response time is rapid instead of slow .