light BMW X5 2003 E53 Workshop Manual

3
Body
The design of the X5 originated in California at BMW’s Design Works. The SAV look was
further developed and refined in Munich. Traditional BMW features such as the Kidney
grilles, quad headlights, reverse link rear side window trim and typical rear tail light treat-
ment allow the X5 to assume a BMW identity. Yet the unique side and hood treatments as
well as the large wheel house openings and high ground clearance set the X5 apart as its
own distinctive vehicle.
The design criteria for the X5 was to develop a vehicle with the superb handling and sporty
driving characteristics that are typically BMW, yet produce an all wheel drive vehicle that can
also be used off-road. This was achieved through the use of independent front suspension
and multi-link rear suspension components that are taken from the E38/E39 vehicle design
and expanded by the addition of front drive components.
The entire body shell/frame assembly of the
X5 is reinforced to ensure optimized body
rigidity.
In addition to the cross bracing on the front
suspension/engine carrier, an additional
panel is installed between the bulkhead and
transmission tunnel.
The floor pan of the X5 is reinforced with
additional ribbing and cross braces to
increase the lateral rigidity. A continuous seat
cross brace is connected to the floor pan
and side sill for reinforcement.
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41530002
Cross
Brace
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Reinforcement Panel

6
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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41530005
63530001

7
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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10
Interior
Located above the windshield in the center is the overhead console that contains the uni-
versal remote switch panel, interior lighting/map panel, sunroof switch and grille for the tele-
phone hands-free microphone. The light panel contains a single bulb which is controlled by
the ZKE, as well as two map reading lamps. The switch provides a ground signal which the
GM recognizes as a request to either turn the interior lights on or off. If the switch is held >
3 seconds, the lights are switched off in the work shop mode as on other models.
Incorporated into the overhead con-
sole, behind the universal remote
switch, is a sunglass storage com-
partment
1
23
63530001
63530002
Sunroof SwitchMicrophone
Right Map LightLeft Map Light
Interior Light
Sunglass Holder
Universal Remote

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

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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

Air Springs
The air spring is made from a flexible rubber material. It
forms an air tight cavity which provides the calculated spring
rate required for the sport wagon.
As the spring compresses downward the bottom edge of
the rubber material rolls along the vertical surface of the
base mount cylinder.
Air is added or removed from the air spring through its top
port. The top port of each spring is connected to a reser-
voir and the air supply pipes. The reservoirs are required to
hold additional air due to the compact design of the springs.
Rear Axle Level Sensors
Hall effect sensors are mounted on the left
and right sides of the rear suspension for ride
height detection. They are pivoted by a cou-
pling rod through the rear axle swing arms.
The hall sensors produce a varying voltage
input to the control module as the suspension
height changes.
If the vehicle is equipped with Xenon head-
lights the right side sensor contains an addi-
tional sensor for the automatic headlight level
adjustment system.
Warning Display
If the system is faulted and off-line or set in the transport mode, the following is displayed:
High Cluster: A message is posted in the high cluster matrix display.
E39 Features 07
37

48
Wheels and Tires
Light alloy wheels are standard equipment on the X5.
The wheels sizes include:
3 Liter version
• Standard Wheel - 7.5J x17 SEH2
• Standard Tires - 235/65R - 17 H rated all season
Front and Rear
4.4 Liter version standard suspension
• Standard Wheel - 8.5J x 18 EH2
• Standard Tires - 255/55R - 18 H rated all season
Front and Rear
4.4 Liter version sports suspension
• Standard Wheels - 9J x 19 EH2 FRONT
10J x 19 EH2 REAR
• Standard Tires - 255/50R -19 Front/285/45R - 19
Rear V rated
The X5 uses a two piece lug bolt that incorporates a spacer wash-
er and features anti-corrosion coating. The tightening torque on the
lug bolts is 130Nm +/- 10Nm. Advantages of using the spacer
washer include:
• Longer expansion length for the bolt.
• A better fit to the wheel
• The spacer washer is fixed to the wheel when tightening and
the lug bolt turns relative to it.