wheel BMW X5 2004 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

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.
00530000

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.
41530001
41530002
Cross
Brace
41530003
Reinforcement Panel

28
Drivetrain
The transfer case, driveshafts, final drives and half shafts make up the drivetrain assembly.
The transfer case is always mounted in the same position on the X5. This applies to other
markets and future models that will utilize different transmissions for different engine con-
figurations. With these models, the transmission tail shafts will be modified to match up with
the transfer case.
The rear driveshaft is a two piece unit using a center bearing, while the front drive shaft is
a single piece that is splined to the transfer case and bolted to the front differential.
The breather vents for both differentials and the transfer case are mounted higher up on the
chassis to prevent water from entering if the vehicle is driven off road through water. The
front breather passes up into the engine compartment and is mounted under the left side
ignition coil cover. The rear breather passes along the under side of the body and is mount-
ed behind the left side wheel arch cover. The breather vent for the transfer case is mount-
ed up high in the driveshaft tunnel.
26530010.jpg
26530011.jpg

29
Drivetrain-Transfer Case
The transfer case is manufactured by New Process Gear Division of New Venture Gear
Company. It is identified as model NV 125.
It incorporates a planetary gear set and chain to provide the torque split and all wheel drive.
The output torque of the transmission is applied to the planetary carrier of the gear set. The
rear drive shaft is connected to the annulus gear and the front drive shaft is connected to
the sun gear through the chain drive.
As the output shaft of the transmission turns, the planetary carrier rotates, causing the
planetary gears to drive the sun gear and annulus gear.
A torque split of 68% rear/ 32% front is provided through the gearing of the planetary set.
26530003
26530004

33
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

35
Overview of EHC Control System
The control philosophy of EHC is to "Initiate a control sequence only when necessary". The
system offers the following advantages:
• The control system operates independently from the vehicle’s engine (no engine driven
hydraulic pump system as per previous self leveling systems).
• Individual control of the rear wheels is possible
• An uneven load is identified and compensated for
• Uneven road surfaces are identified and not compensated for
• Automatic control is interrupted when cornering
• The system is diagnosable using the DIS or MoDiC
The air suspension system consists of the following components:
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45
DIS/Modic Service Funnction Program
The Service Functions program of the DIS/MoDiC provides the Transport Mode activa-
tion/deactivation and Ride Height Offset functions (see next page).
Once the transport mode has been released, or if the system requires left to right side
height adjustment, the ride height "OFFSET" must be carried out to ensure that the vehi-
cles suspension has a base ride height level starting point.
The "HEIGHT OFFSET" is adjusted using the DIS or MoDiC. The procedure is as follows:
• Place the vehicle on a level surface unloaded.
• Access the Height Offset program in the service function menu.
• Measure the base ride height from the lower edge of the wheel housing to the center of
the wheel hub.
• Check measured height against the specifications listed
• Use the DIS/MoDiC to correct the ride height if the value differs from the listed specifi-
cation.

46
Steering
The X5 utilizes a power assisted rack and pinion steering system due to all wheel drive con-
siderations. The power steering pump is a vane cell design.
The turning radius of the X5 is 12.2 meters.
The steering column is electrically adjustable for length and height that includes the mem-
ory function incorporated into the seat/mirror memory system.
32530006
Steering Column
Electrically Adjustable

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.