Air BMW X5 2003 E53 Workshop Manual

2
Introduction
The X5 marks BMW’s introduction into the luxury “Sports Activity Vehicle (SAV)” niche seg-
ment of the Sport Utility Vehicle market. While carrying the designation X5, the vehicle is not
based on the 5 Series but it is its own new car-like platform. The X5 is offered with two
engine variants:
• The 4.4 liter M62 TU engine equipped with the A5S 440 Z automatic transmission.
• The 3 liter M54 engine with either the GM 5 automatic or 5 speed manual transmission
The X5 incorporates the following
features:
• Four wheel independent sus-
pension (BMW tradition)
• Full time - all wheel drive
(planetary gear transfer case)
• All road vehicle (ON/OFF road
capabilities)
• High ground clearance
• Unitized body and Chassis
(car like ride and handling)
• Double pivot front suspension
• “Integral Link” rear suspen-
sion with air spring self level-
ing
• X5 specific traction control
system
Two different suspension options are offered (standard and sport) with different springs,
shock absorbers and stabilizers.
The X5 has 180 mm ground clearance, for both suspensions to allow off road travel.
However, the suspension travel is the same as the E39 which allows the X5 to retain a car
like feel when driven every day.
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Hood/Front Grille
The hood on the X5 is distinctive, with two IHKA air intake hood scopes in the center lead-
ing down to the traditional BMW twin grilles.
The grilles are integrated into the hood with
the secondary hood latch springing out from
the grille when the hood is opened.
The four round headlights complete the front
end with Xenon low beans as an option for
the X5. The fog lights as well as the headlight
washers are integrated into the bumper.
Hood Scoops
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Climate Control Systems (IHKR/IHKA)
Two climate control systems are offered on the X5, the manual IHKR system is standard
equipment on the 3 liter X5 and the IHKA system is available as an option. The IHKR is a
new system for US production and the IHKA is taken from the E39 vehicles.
Condenser/Receiver Dryer
The X5 incorporates a new design air conditioning condenser/receiver dryer for both the
manual (IHKR) and the automatic (IHKA) systems. The dryer cartridge and condenser are
one component with the dryer integrated on the left side. The dryer cartridge contains a
replaceable filter screen and dryer unit.
The condenser is partitioned which divides the condenser into cooling sections. The hot
refrigerant flows across the condenser and into the dryer through inlet holes at the lower
1/3 section of the cooling fins. After the refrigerant passes through the dryer it returns to
the evaporator through the outlet hole and bottom 1/3 section of the condenser.
Condenser Side View
Receiver Dryer
Filter
Screen
Bottom View
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Climate Control System (IHKR)
The manual system is controlled through the use of bowden cables for air distribution and
electronic control for temperature regulation and blower speed. One stepper motor is used
for the fresh/recirculated air intake.
The IHKR incorporates the following features:
• Fresh air intake grilles integrated into the hood - the fresh air passes through the single
micro filter installed in the center of front bulkhead.
The air then passes through the air duct, which is bolted to the bulkhead, and enters the
heater - A/C unit through the non-return flaps.
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Intake
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IHKR Control Unit
• Integrated control module with oper-
ating panel.
• IHKR heater/air conditioner unit with
- 1 heat exchanger temperature sensor
- 1 evaporator temperature sensor
- 1 footwell temperature sensor
- Blower motor
- 1 stepper motor (high speed fresh/rcirc air)
45
80 72
TEMP
0
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IHKR Operation
IHKR system operation is as follows:
• Temperature Control - The desired interior temperature is set with the rotary knob on the
control panel. Control of the interior temperature is carried out electronically by the con-
trol module’s cycling of the water valve to regulate coolant flow through the heat
exchanger.
• Air Distribution - Air distribution is set mechanically through the use of gear linkages and
bowden cables. The air can be set for:
- Footwell or blended between footwell/face vent or footwell and defrost
- Defrost or blended between footwell/defrost or defrost/face vent
- Face vent or blended between face vent/footwell or face vent/defrost
• Blower Control - Blower fan speed is controlled through a final stage with infinitely vari-
able speed control.
The push buttons on the control panel are used to:
• Switch between fresh air and recirculating air inlet modes
• Request for A/C activation
• Activation of the rear window defogger
45
80 72
TEMP
0
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45
80 72
TE MP
M
+
+
+
½
P
1
204060801001201400234
5
6
7!ABS
    
  









 
mi le s0
10 15 20 40+
DME
M
KL31
KL30
KL15
Fan Speed
Request
A/C Compressor
Recirculation
Rear Defrost
Temperature
Control
Evaporator
Temperature SensorWasher Jet Heater
Blower Relay
Blower
Blower Motor Ouput Stage
M
Rear Window Defoger Relay
Aux. Fan Speed Relay Control
Water Valve
Fresh Air Flap Motor
IKE
DME
Compressor Control
Aux. Fan
IHKR
K-Bus
Refrigerant Pressure Sensor
C
A
N
DIS & Modic
IHKR IPO
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Climate Control System (IHKA)
The IHKA is standard equipment on the X5 with the M62 engine and optional equipment
on the M54 version. The IHKA system is taken from the E39 sedan and includes all func-
tions and features of the IHKA currently installed in the E39.
Features of the IHKA system include:
• Integrated control panel/module.
• Separate temperature control for the driver and front passenger.
• Air flap control through the use of bussed stepper motors.
• Automatic Recirculation Control (AUC).
• Recirculation air flap control from the MFL.
• “REST” function for residual heat when vehicle is stopped.
• Service station feature that closes the water valves when stopped to prevent hot water
circulating into the heater cores.
• A/C compressor clutch activation through a final stage control.
• Center face vent stratification control through a bowden cable.
• Separate blower motor for rear passenger compartment
The rear blower motor is located below the center storage box behind the center air outlet
grilles. The blower speed control is mounted in the panel below the outlets. Cool or strati-
fied air is available at the center outlets.
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IHKA Air Flow
The micro filter for the IHKA system is installed in the engine compartment in the center of
the fire wall.
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Warm Air Flow
Stratified Air Flow
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Cargo Area
The full size spare tire is mounted
below the load floor with the LVA air
supply system for the air springs
located beneath the spare.
The battery is mounted below the LVA
in a molded plastic battery box, along
with the EHC control module and the
PDC control module. If the optional
trailer towing package is installed, the
trailer module is also installed in the
module carrier.
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