EGR BMW X5 2003 E53 Workshop Manual

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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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Doors/Mirrors
The doors on the X5 incorporate side bars which serve as side impact protection without
the use of the metal hooks found on the sedans. The mirrors are aero style that includes
cascade lighting at the bottom of the mirror for vehicle entry at night. The lights are
switched on when the vehicle is unlocked to light the ground around the door.
Running boards, integrated into the rocker panels, provide ease of entry on the left and right
sides.
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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.
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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
Fresh Air

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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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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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Front Suspension
The front suspension design is taken from the E38/E39 double pivot system. The compo-
nents are larger in size and made from all steel for the expected harder use that the X5 sus-
pension will receive. This includes the sub-frame which is also larger in size and supported
by two hydraulic mounts for vibration absorbion. The front suspension carrier incorporates
an aluminum stiffening plate that is bolted to the carrier. It adds to the front axle kinematics
by reducing flex in the front suspension. It also provides protection for the oil pan and front
end components when off-road and improves the Cd by providing a smooth surface for air
flow under the vehicle.
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Front Axle Technical Data
TRACK: 1576mm
TOE-IN: 18’ +/-10’
CAMBER: -12’ +/- 20’
S.A.I: 12 Degree’s 48 Feet
CASTER: 7 Degree’s 8 Feet

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Rear Suspension
The rear suspension is the “intragal” multi-link design taken from the E38/E39 vehicles.
Several components AER made from aluminum to erduce the unsprung weight. The X5
with the M62TU engine uses the EHC (air spring) suspension system. The EHC functions
the same as the E39 Sport Wagon with only minor differences to the components and lay-
out of the system. The X5 with the M54 engine will use standard springs in the rear with the
EHC system as an option. The rear struts on the X5 are mounted to the body instead of
the sub-frame.
The rear axle sub-frame is mounted to the body through four bushings (larger than E38) for
increased load and comfort. The rear differential is mounted through three rubber bushings
two in the front and one hydromount in the rear. The wheel bearings are similar to the E39
but incorporate different seals - designed for off-road use.
New special tools are available for adjusting the rear suspension due to the limited space.
Rear Axle Technical Data
Track: 1576mm
Toe In: 18 Feet
Camber 1 Degree 50 Feet