Parts and Accessories Installation Instructions

Transcription

1 Parts and Accessories Installation Instructions F 53 7 W Retrofit auxiliary heating system BMW X5 (E 53) with M57 engine (diesel) The installation time is approx hours (see important information), but this may vary depending on the condition of the car and the equipment in it. Retrofit / Installation kit No Retrofit / Installation kit No Installation Instructions No Issue date:.

2 Contents Section Page Important information Preparations Installation and cabling diagram Auxiliary heating system wiring harness connection overview To install and connect the auxiliary heating system wiring harness To install the remote control components To install the time switch To modify the coolant system Concluding work and coding To operate the auxiliary heating system To service the auxiliary heating system Auxiliary heating system E53 with M57 engine circuit diagram Retrofit / Installation kit No Installation Instructions No Issue date:. EN/

3 Important information The retrofit kit is for use within the BMW dealership organisation only. In addition to the basic kit the control element required by the customer must be ordered separately. The wiring harness supplied with the installation kit is only to be fitted if there is no white/green cable on the 6-pin plug X764 (on the auxiliary heater). If the wiring harness is required, the installation time required will increase to approx. 4.5 hours. On cars without a high on-board computer or on-board monitor the auxiliary heating system can only be operated using the remote control, the Thermo Call or the time switch. Do not kink or damage the cables during the installation work since otherwise they may cause faults that can later only be identified by extensive additional work. The costs incurred as a result of this will not be reimbursed by BMW. If the specified PIN chambers are occupied, bridges, double crimps or twin-lead terminals must be used. After the installation work the retrofit auxiliary heating system must be coded using DIS or MoDiC via the Retrofit path. Target group The target group for these installation instructions is specialist personnel trained on BMW cars with specialist knowledge of vehicle electrical systems. Work: All servicing, repair and installation work on BMW cars is completed at your own risk. All work is to be carried out using current BMW - Repair manuals - Circuit diagrams in a rational order using the prescribed tools (special tools) and observing current health and safety regulations. Information on operation Operating the auxiliary heating system places a strain on the car s battery. To avoid starting problems and to stabilise the car s electrical system we recommend that you drive the car adequately in the period when you use the auxiliary heating system so that the battery remains well charged. Recommendation: 3 minutes auxiliary heating system use = 3 minutes driving time.! Danger of poisoning! The auxiliary heating system must not be operated in enclosed areas such as garages or workshops (not even using the time switch or remote control). The auxiliary heating system must be switched off at filling stations and/or filling points to eliminate the risk of explosions. Required tools and equipment Set of flat screwdrivers Set of Torx wrenches Set of Allen keys Crimping pliers for AMP contacts DIS or MoDiC Set of Philips screwdrivers Torch /4 inch reversible ratchet set Angle cutter Set of open-ended/ring spanners Retrofit / Installation kit No Installation Instructions No Issue date:. EN/3

4 . Preparations TIS instruction No. Conduct a brief test Disconnect the negative pole of the battery... The following components must be removed first of all Heating closing panel Also remove the following components if you wish to install the remote control: Boot trim on the right. C pillar trim on the right Boot floor trim 5 47 Also remove the following components if you wish to retrofit the auxiliary heating system wiring harness or the time switch: Trim at the bottom left of the instrument panel Glove compartment Trim at the bottom right of the instrument panel Rear seat bench Bottom side trim on the A pillar in the passenger footwell Pedal trim Centre console side trims 5 6 Door sill strips on the inside right 5 47 Retrofit / Installation kit No Installation Instructions No Issue date:. EN/4

5 . Installation and cabling diagram F W Legend Auxiliary heater Auxiliary heating system wiring harness (only required if there is no white/green cable on the 6-pin plug X764 (on the auxiliary heater)). 3 Adhesive aerial 4 Auxiliary heating system remote control receiver fuse 5 Remote control receiver 6 Time switch Retrofit / Installation kit No Installation Instructions No Issue date:. EN/5

6 3. Auxiliary heating system wiring harness connection overview B C A D F W Item Description Signal Auxiliary heating system wiring harness A Blade terminal contact SH controller B Blade terminal contact Terminal 3 C 6-pin socket casing --- D Joint connector contact Terminal 3 Cable colour / Cross-section Connection location in the car Abbreviation / Slot GN/WS On auxiliary heater X764, PIN.5 mm RT/SW To fuse holder in the boot on the right X7, fuse slot.75 mm F86 WS/GN To auxiliary heater A4, black 6-pin plug X764, PIN.5 mm BR, Joint connector on rear closing panel X493.5 mm Retrofit / Installation kit No Installation Instructions No Issue date:. EN/6

7 4. To install and connect the auxiliary heating system wiring harness The wiring harness is only to be fitted if there is no white/green cable on the 6-pin plug X764 (on the auxiliary heater). Connect branch D, brown cable on joint connector X493 to the rear closing panel. D X Z Remove the screws () and swing the fuse box () to the side. F 53 3 W B Lay branch B, red/black cable, to the fuse box. Take out fuse holder () and push out the interlock (). Connect branch B, to slot F86. Insert the 5A fuse (3) into slot F Z Lay branch A, white/green cable in the right side skirt towards the glove compartment and then behind the heating box to the left-hand side of the car. A Lay branch A, green/white cable through the seal () into the engine compartment to the auxiliary heater. 53 Z Retrofit / Installation kit No Installation Instructions No Issue date:. EN/7

8 4. To install and connect the auxiliary heating system wiring harness Disconnect both plugs from the auxiliary heater (). X764 Lay branch A, white/green cable, to plug X764 (). A 53 3 Z Push in the interlock () and move the fuse () to one side. Connect branch A white/green cable, to PIN.! First connect the -pin plug to the auxiliary heater to prevent static electric charging. Lock plug X764 again and connect both plugs to the auxiliary heater Z Retrofit / Installation kit No Installation Instructions No Issue date:. EN/8

9 5. To install the remote control components! Ensure that you do not kink the air lines in the air supply system (). Remove the screws () and swing the air supply system () to the side. F W Remove the screws () take out the cover (). F 53 4 W Remove the screws (). Undo the screw (). Remove the retaining plate (3). 3 F 53 4 W Push the holder () on to the remote control receiver (). F 39 7 W Retrofit / Installation kit No Installation Instructions No Issue date:. EN/9

10 5. To install the remote control components 3 Hold the remote control receiver () in position as shown, mark the hole on the retaining plate () and drill a 6 mm hole. Secure the remote control receiver () with a hexagonal screw M 5 x mm and a hexagonal nut (3). Fit the retaining plate () again. 4 F 53 W 3 The gluing temperature must be at least C. Clean the side window in the area where the aerial is to be affixed. Affix the adhesive aerial () as shown. Lay the aerial cable () along the standard wiring harness (3) to the installation site of the remote control receiver. F 53 6 W Cars with a plug fitted as standard for the remote control only: X883 Release plug X883 from the wiring harness. Disconnect all the cables from the plug () Z Connect the disconnected cables () into the 6-pin plug casing X883 from the installation kit as follows. X883 PIN PIN 3 PIN 6 red/black cable white/green cable brown cable 53 6 Z Retrofit / Installation kit No Installation Instructions No Issue date:. EN/

11 5. To install the remote control components All cars X883 Connect the aerial cable () and plug casing X883 to the remote control receiver (). Secure the cables with cable tape (3) Z Retrofit / Installation kit No Installation Instructions No Issue date:. EN/

12 6. To install the time switch Only install the time switch installation kit if the car is not equipped with a high on-board computer or on-board monitor. X883 Release plug X883. Connect the black cable () on the time switch wiring harness to PIN 4. Cut the brown and red/black cables ( and 3) approx. 5 cm away from plug X F W 3 Fit the cable ends of the cut cables (3 and 4) with plug and socket contacts. Connect branches ( and ) on the time switch wiring harness to the cut cables of the same colour. 4 Lay the time switch wiring harness on the righthand side of the car along the standard wiring harness to the front and then to the driving light switch. F 53 9 W Affix the template as shown. Make holes as shown on the template. F W Retrofit / Installation kit No Installation Instructions No Issue date:. EN/

13 6. To install the time switch 4 5 Secure the engagement pin () with a self-tapping screw () 3.5 x 6 mm. Affix the foam seal (4) to the time switch (5) from the rear. Thread the 4-pin plug X3 through the hole (3) and connect it to the time switch (5). 3 X3 F W Retrofit / Installation kit No Installation Instructions No Issue date:. EN/3

14 7. To modify the coolant system F W Remove the coolant hoses ( and ). Retrofit / Installation kit No Installation Instructions No Issue date:. EN/4

15 Z 7. To modify the coolant system Place the damper bearing (4) on the coolant hose or non-return valve as shown (to prevent chafing). Complete the water system using the coolant hoses ( and ) and the non-return valves supplied in the installation kit. Retrofit / Installation kit No Installation Instructions No Issue date:. EN/5

16 7. To modify the coolant system 3 Connect the coolant hoses ( and 3) to the holder () from the installation kit. 53 Z Retrofit / Installation kit No Installation Instructions No Issue date:. EN/6

17 8. Concluding work and coding Connect the battery. Fill and bleed the coolant system as per the instructions. Code the auxiliary heating system using DIS or MoDiC via path Retrofit. Check the function of the auxiliary heating system. Assemble the car again following the instructions to dismantle it in reverse order. Retrofit / Installation kit No Installation Instructions No Issue date:. EN/7

18 9. To operate the auxiliary heating system The instructions for operating the auxiliary heating system with the on-board computer or on-board monitor are described in the owner s handbook supplied with the car and are to be taken from there. The instructions for operating the auxiliary heating system with the Thermo Call are described in the separate Thermo Call installation instructions. The section headed Operation is described again separately for the customer. Please cut out this section and enclose it with the vehicle documents. 3 To program the hand-held transmitter - Pull fuse F86 out of the fuse holder - Wait for at least 5 seconds - Insert fuse F86 again - Press the OFF key () on the hand-held transmitter for at least second within 5 seconds. This completes the programming procedure. Up to three hand-held transmitters can be programmed to operate with one receiver. F W To switch on the auxiliary heating system - Press the ON key () on the hand-held transmitter for at least second. - The LED (3) lights up briefly during the transmission process and then flashes during the switch on procedure. To switch off the auxiliary heating system - Press the OFF key () on the hand-held transmitter for at least second. The LED (3) will light up briefly during the transmission procedure. The two available versions T7 (blue control keys) and T8 (wine red control keys) differ in that the T8 version sends a response from the remote control receiver in the car to the hand-held transmitter. The two versions are to be used in exactly the same way. Response after transmission (T8 only) - LED (3) flashes for seconds after transmission - LED (3) flashes for seconds after transmission Meaning - Signal not received, change position and retransmit - Signal received If the range becomes less, change the batteries (type MN) in the hand-held transmitter. Retrofit / Installation kit No Installation Instructions No Issue date:. EN/8

19 9. To operate the auxiliary heating system F M To switch on the auxiliary heating system - Manual Press the Heat now key (4) - Automatic by programming the start time Operating indicator - The heating indicator (5) and orange display light are lit during the entire heating period. To switch off the auxiliary heating system - Manual Press the Heat now key (4) - Automatic By the programmed duration on the time switch - The heating indicator (5) and orange display light will go out. To set the time - Press the time key (8) briefly and then press forwards () or backwards (3) until the required time appears. Release the key. The longer you press the keys, the faster the numbers for the time will move. To display the time - Press the time key (8) briefly. The time display will go out after seconds. To program the start time Three different start times can be programmed. - Press the key () once and program the first start time using the following table. -:-- or a time will appear on the display (6). - Press forwards () or backwards (3) until the required start time appears on the display (6). The entered start time will go out after approx. 8 seconds. - If you press and hold forwards () or backwards (3) for more than seconds the displayed time will be deemed to have been selected and will be saved. - Press key () again to program the other start times. A start time has been programmed if the program number (7) is displayed and the orange display light is lit permanently. The brightness of the display light cannot be adjusted. Retrofit / Installation kit No Installation Instructions No Issue date:. EN/9

20 9. To operate the auxiliary heating system To delete the start time - Press the time key () briefly. The start time in the display (6) will disappear. Select the programmed start time - Press key () within seconds until the program number with the required start time is displayed. Retrofit / Installation kit No Installation Instructions No Issue date:. EN/

21 . To service the auxiliary heating system Refer to the operating instructions in the owner s handbook. Check the charge condition of the battery on cars that are predominantly driven short distances and recharge it if necessary. Subject to technical modifications. Retrofit / Installation kit No Installation Instructions No Issue date:. EN/

22 . Auxiliary heating system E53 with M57 engine circuit diagram A46 A F59 A48 5A F86 X456 3 X7 X65,5 RT GE,5 br N5 3 X3 X64 X64,5 RTSW A4 6 X764,75 SW RT,35 WS RT GE,35 WS GN,75 RT SW,5 SW,75 BR X6 X X883 M Y7 A8 6 X883,5 BR,5 BR X493 F W Retrofit / Installation kit No Installation Instructions No Issue date:. EN/

23 . Auxiliary heating system E53 with M57 engine circuit diagram Legend A4 A46 A48 A8 N5 X65 X493 X64 X764 X997 X7 X6 X3 X456 X883 Y7 Auxiliary heater control module Front fuse holder Rear fuse holder Auxiliary heating system remote control receiver Time switch Earth Earth -pin black plug on the auxiliary heater 6-pin black plug on the auxiliary heater -pin black plug on the metering pump Rear fuse holder K bus joint connector 4-pin black plug on the time switch Front fuse holder 6-pin black plug on the remote control receiver Metering pump Cable colours RT SW GN BR GE WS red black green brown yellow white Retrofit / Installation kit No Installation Instructions No Issue date:. EN/3

24 To operating the auxiliary heating system with remote control T7 (blue control keys) 3 To program the hand-held transmitter - Pull fuse F86 out of the fuse holder - Wait for at least 5 seconds - Insert fuse F86 again - Press the OFF key () on the hand-held transmitter for at least second within 5 seconds. This completes the programming procedure. Up to three hand-held transmitters can be programmed to operate with one receiver. F W To switch on the auxiliary heating system - Press the ON key () on the hand-held transmitter for at least second. - The LED (3) lights up briefly during the transmission process and then flashes during the switch on procedure. To switch off the auxiliary heating system - Press the OFF key () on the hand-held transmitter for at least second. - The LED (3) will light up briefly during the transmission procedure. If the range becomes less, change the batteries (type MN) in the hand-held transmitter. Retrofit / Installation kit No Installation Instructions No Issue date:. EN/4

25 To operating the auxiliary heating system with remote control T8 (wine red control keys) 3 To program the hand-held transmitter - Pull fuse F86 out of the fuse holder - Wait for at least 5 seconds - Insert fuse F86 again - Press the OFF key () on the hand-held transmitter for at least second within 5 seconds. This completes the programming procedure. F W Up to three hand-held transmitters can be programmed to operate with one receiver. Response after transmission Meaning - LED (3) flashes for seconds after transmission - Signal not received, change position and retransmit - LED (3) flashes for seconds after transmission - Signal received To switch on the auxiliary heating system - Press the ON key () on the hand-held transmitter for at least second. - The LED (3) lights up briefly during the transmission process and then flashes during the switch on procedure. To switch off the auxiliary heating system - Press the OFF key () on the hand-held transmitter for at least second. - The LED (3) will light up briefly during the transmission procedure. If the range becomes less, change the batteries (type MN) in the hand-held transmitter. Retrofit / Installation kit No Installation Instructions No Issue date:. EN/5