Original BMW Accessories. Installation Instructions.

Transcription

1 Original BMW Accessories. Installation Instructions. Removable trailer tow hitch retrofit BMW 3 Series Saloon (F30) BMW 3 Series Touring (F3) BMW 4 Series Coupé (F32) BMW 4 Series Gran Coupé (F36) These installation instructions apply to cars built after 3/204 only. The trailer tow hitch retrofit is not possible on F3 cars with 20" SZ wheels (special accessory). Retrofit kit number Electrical components retrofit kit Trailer tow hitch removable Installation time The installation time is approx. 2.5 hours. On cars without the fuse box high already installed, the installation time increases by around hour. This may vary depending on the condition of the car and the equipment in it. The right-hand rubber engine mount must be replaced in cars with an N55 engine without xdrive. This increases the installation time by approx..25 hours. The fan frame and fan must be replaced on various cars. This increases the installation time by approx hours. The installation time shown does not include any time spent on programming / coding. The calculation of the total costs for the programming time must be factored into the calculation of retrofitting costs (no charges may be made through the warranty). Important information These installation instructions are primarily designed for use within the BMW dealership organisation and by authorised BMW service companies. In any event, the target group for these installation instructions is specialist personnel trained on BMW cars with the appropriate specialist knowledge. All work must be completed using the latest BMW repair manuals, wiring diagrams, servicing manuals and work instructions, in a rational order, using the prescribed tools (special tools) and observing current health and safety regulations. If you experience installation or function problems, restrict troubleshooting to approx. 0.5 hours for mechanical work and.0 hour for electrical work. To avoid unnecessary extra work and/or costs, send an inquiry straight away to the technical parts support team via the Aftersales Assistance Portal (ASAP). Quote the following information: Vehicle identification number, Retrofit kit part number, A detailed description of the problem, Any work already carried out. Do not archive the hard copy of these installation instructions since daily updates are provided via ASAP! /22

2 Pictograms Denotes instructions that draw your attention to dangers.! Denotes instructions that draw your attention to special features. Denotes the end of the instruction or other text. Information for the customer The sections entitled "Customer information" and "Statutory regulations pursuant to EC Directive 94/20/EC" at the end of these Installation Instructions must be printed out and given to the customer. Legal requirements A type approval in accordance with EC Directive 94/20/EC Annex VII exists for the trailer tow hitch, with EC homologation mark e3*55r00*55r0*3484*00. If you comply with these regulations and notes in these installation instructions, no special acceptance test pursuant to 9 of the German Road Traffic Licensing Directive and no special entry in the vehicle registration document is necessary. The ball head must be removed when it is not in use. Installation information! The fan frame and fan will need to be replaced on certain models of vehicle.! The right-hand rubber engine mount must be replaced in cars with an N55 engine without xdrive. Ensure that the cables and/or lines are not kinked or damaged as you install them in the car. Costs arising from this will not be reimbursed by BMW AG. Additional cables/wires that you install must be secured with cable ties. If the specified PIN chambers are occupied, bridges, double crimps or twin-lead terminals must be used. All pictures show LHD cars; proceed accordingly on RHD cars. After the installation work, the retrofit must be programmed / coded via the Conversions path. Replacing the fuse box If PIN and PIN 3 of plug Z2*8B are not occupied in factory-installed rear fuse box Z2, fuse box high U must be installed. Ordering instructions Heat shield J, sheet metal nuts I and screws L are not supplied with the retrofit kit and must be ordered separately for cars without the N47 engine (for part numbers and details, see EPC). Module holder P and control unit R are not included in the retrofit kit and must be ordered separately (see EPC for part number and further details). The fan frame and fan will need to be replaced on certain models of vehicle. This must be ordered separately (for part number and instructions, see EPC-HG 7). The right-hand rubber engine mount must be replaced in cars with an N55 engine without xdrive. The right-hand rubber engine mount is not included in the retrofit kit and must be ordered separately (for part number and instructions, see EPC-HG 22). 2/22

3 List of special equipment The following special equipment must be taken into consideration when installing the retrofit kit SA 465 Through-loading system Special tools required Details of the special tool required can be found in the relevant ISTA repair manual. 3/22

4 Chapter Page. Parts list for retrofit kit Preparatory work Retrofit wiring harness connection diagram Auxiliary cable connection diagram (only for cars without the high fuse box already installed) Installation and cabling diagram Installing the towing hitch Installing and connecting the retrofit wiring harness Concluding work and coding Wiring diagram Customer information Statutory regulations pursuant to EC Directive 94/20/EC /22

5 . Parts list for retrofit kit A B H G F E O N W P C I Q J R S D K T U Y X L M V Z F Z Legend A B C D E F G H I J K L M N O P Q R S T U V W X Y Z Retrofit wiring harness Trailer tow hitch Socket swivel device M2 hexagon nut (4 x) Socket Pan head screw M5 x 40 mm (3 x) Hex nut M5 (3 x) Clip (only for cars without N47 engine) Sheet metal nut (3 x, only for cars without N47 engine, not supplied with the retrofit kit) Heat shield (only for cars without N47 engine, not supplied with the retrofit kit) Speed nut (2 x, only for cars without N47 engine) Screw (3 x, only for cars without N47 engine, not supplied with the retrofit kit) Hex screw (4 x, only for cars without N47 engine) Cable tie (5 x) Miniature connector (4 x) Module holder (not supplied in the retrofit kit) Plastic nut (2 x, not supplied with the retrofit kit) Control unit (not supplied in the retrofit kit) SW 7-pin socket casing VI 7-pin socket casing Fuse box high (only for cars without fuse box high already installed at the rear) Fuse 20 A (3 x) Ball head Storage bag Auxiliary cable (only for cars without the fuse box high already installed at the rear) GR 6+6-pin socket casing (only for cars without the rear high fuse box already installed) 5/22

6 2. Preparatory work ISTA No. Disconnect the negative terminal of the battery The following components must be removed first of all Rear bumper trim Support for rear bumper trim (no longer required) Guide for the rear right bumper trim Luggage compartment floor trim Luggage compartment wheel arch trim, right Rear fuse box (release only) Only cars without rear high fuse box already installed Rear seat bench Rear right (interior) door sill cover strip Bottom right B-pillar trim Front right (interior) door sill cover strip Bottom right A-pillar trim Replace the rear fuse box Only if the fan frame and fan must be replaced Replace the fan frame with fan For cars with N55 engine without xdrive only Replace the right-hand rubber engine mount /22

7 3. Retrofit wiring harness connection diagram A8 A7 A9 A6 A A0 A A A4 A2 A5 A2 Item Designation A3 F Z Signal Cable colour/ cross-section Connection location in the car Abbreviation/ slot A Retrofit wiring harness A SW 3-pin socket casing A2 Cable open Terminal 54M SW/GE 0.75 mm² With miniature connector O to connector X86*V on plug REM A74 A74*2B PIN 8 A3 Cable open Terminal 49R SW/GR 0.75 mm² With miniature connector O to connector X300*V on plug REM A74 A74*2B PIN 2 A4 Socket contact B-CAN_H GE/RT 0.35 mm² Connect to the plug on REM A74 A74*4B PIN 3 A5 Socket contact B-CAN_L GE/BR 0.35 mm² Connect to the plug on REM A74 A74*4B PIN 46 A6 M6 ring eyelet Terminal 3 BR To ground support point, right-hand rear wheel arch A7 SW 24-pin socket casing To control unit R A255*B A8 SW 6-pin socket casing To control unit R A255*2B To control unit R A255*3B To socket E Z0*9B A9 SW 0-pin socket casing A0 Socket contact Terminal 30B_F39 RT/SW 2.50 mm² To rear fuse box Z2 Z2*9B PIN 4 A Socket contact Terminal 30F_F3 RT/BL 2.50 mm² To rear fuse box Z2 Z2*3B PIN 5 A2 Socket contact Terminal 30F_F4 RT/GE 2.50 mm² To rear fuse box Z2 Z2*3B PIN 4 7/22

8 4. Auxiliary cable connection diagram (only for cars without the high fuse box already installed) Y Y Y3 Y2 Y4 F Z Y Auxiliary cable Y Socket contact Terminal 30F OUT BL/GE 0.35 mm² To FEM A73 A73*3B PIN 5 Y2 Socket contact Terminal 30F IN RT/GE 0.35 mm² To FEM A73 A73*3B PIN 4 Y3 Socket contact Terminal 30F OUT BL/GE 0.35 mm² To rear fuse box Z2 Z2*8B PIN Y4 Socket contact Terminal 30F IN RT/GE 0.35 mm² To rear fuse box Z2 Z2*8B PIN 3 8/22

9 5. Installation and cabling diagram Y R A 4/U * E Y* F Z A E R Y Y* Retrofit wiring harness Socket Control unit Auxiliary cable (only for LHD cars without the high fuse box already installed) Auxiliary cable (only for RHD cars without the high fuse box already installed) FEM A73, plug A73*3B (only for LHD cars without the high fuse box already installed) FEM A73, plug A73*3B (only for RHD cars without the high fuse box already installed) REM A74, plug A74*2B and A74*4B Ground support point Z0*9B Rear fuse box, plugs Z2*8B, Z2*9B and Z2*3B Rubber grommet * 2 3 4/U 5 9/22

10 6. Installing the towing hitch When drilling, ensure that you do not damage the cable behind. 35 mm Mark and centrepunch the drilling point () on the right-hand rear side panel (2). 90 mm Drill through the right-hand rear panel (2) at the drilling point () and enlarge the hole using a 40 mm step drill bit. Deburr the hole and coat the bare surfaces with preservative. 2 F Z 2 A Route branch A from the interior through the drill hole and place the grommet () in the drill hole and make it water-tight. N Secure retrofit wiring harness A using cable ties N to the standard vehicle wiring harness (2). A F30 07 Z Note the tightening torque value:.5 2 Nm. B Fit socket swivel device C as shown onto trailer tow hitch B. C F Z Note the tightening torque value: 08 Nm. D D Screw on trailer tow hitch B using hexagon nuts D. B F Z 0/22

11 6. Installing the towing hitch C A The socket cover () must open to the left. Connect branch A, SW 3-pin socket casing, to socket E and secure using pan-head screw F and hexagon nut G to socket swivel device C. E G F F30 08 Z Ensure that retrofit wiring harness A does not interfere with the socket's swivel movements. Do not tie up retrofit wiring harness A too short. A B Secure retrofit wiring harness A using cable ties N to the socket swivel device C and trailer tow hitch B. N C F Z M M B H M Cars without N47 engine only Connect clip H using hexagon screws M in front of the rear silencer () to trailer tow hitch B. Place speed nuts I on clip H. M I F Z Screw on heat shield J with speed nuts K and screws L. L K J F Z /22

12 6. Installing the towing hitch All cars Attach reinforcer () to trailer tow hitch B. B F Z 2/22

13 7. Installing and connecting the retrofit wiring harness A74*4B O A74*2B Connect branches A2-A3 as follows using miniature connector O to the standard vehicle wiring harness on REM A74: Connect branch A2, SW/GE cable, using miniature connector O to the cable from PIN 8 of plug A74*2B, SW 26-pin socket casing A2-A3 A74 A4-A5 F Z Connect branch A3, SW/GR cable, using miniature connector O to the cable from PIN 2 of plug A74*4B, SW 54-pin socket casing Connect branches A4 A5 as follows to plug A74*4B of REM A74: Connect branch A4, GE/RT cable, to PIN 3 of plug A74*4B, SW 54-pin socket casing Connect branch A5, GE/BR cable, to PIN 46 of plug A74*4B, SW 54-pin socket casing If module holder P is already installed, this is not required. P Screw on module holder P using plastic nuts Q. Q F Z Insert control unit R into module holder P. P R F Z 3/22

14 7. Installing and connecting the retrofit wiring harness Connect retrofit wiring harness A as follows: A6 R Connect branches A7-A9 to control unit R Z0*9B A7-A9 A Z2 A0-A2 Screw branch A6 onto ground support point Z0*9B Route branches A0 A2 to fuse box Z2 Secure retrofit wiring harness A using cable ties to the standard vehicle wiring harness F Z Only cars without the fuse box high already installed at the rear If PIN and PIN 3 on plug Z2*8B are not occupied in the factory-installed rear fuse box, fuse box high U must be installed. U Connect branches Y3-Y4 as follows to plug Z2*8B: Z2*8B Y3-Y4 Branch Y3, BL/GE cable, to PIN of plug Z2*8B, GR 6+6-pin socket casing Branch Y4, RT/GE cable, to PIN 3 of plug Z2*8B, GR 6+6-pin socket casing F3 004 Z Route branches Y-Y2 to FEM A73 and connect as follows to plug A73*3B: A73 Branch Y, BL/GE cable, to PIN 5 of plug A73*3B, SW 54-pin socket casing Branch Y2, RT/GE cable, to PIN 4 of plug A73*3B, SW 54-pin socket casing A73*3B Y-Y2 F Z 4/22

15 7. Installing and connecting the retrofit wiring harness All cars Z2*9B A0-A S Z2*3B T F Z Fuses can fall out when plugs are connected to the fuse box (). Ensure that all the fuses are replaced in their correct position. If plugs Z2*9B or Z2*3B are not present, use socket casing S or T. Connect branches A0 A2 as follows: Branch A0, RT/SW cable, to PIN 4 of plug Z2*9B, SW 7-pin socket casing Branch A, RT/BL cable, to PIN 5 of plug Z2*3B, VI 7-pin socket casing Branch A2, RT/GE cable, to PIN 4 of plug Z2*3B, VI 7-pin socket casing Insert fuses V into slots F3, F4 and F39 of the rear fuse box (). F3 F4 F39 V F Z 5/22

16 8. Concluding work and coding The retrofit system requires programming / coding. Connect the battery Connect the battery charger to the car Connect the car to the ISTA workshop system Call up the ISTA/P car programming facility If using ISTA/P, please note the instructions provided in the ISTA/P application documentation Select the "Removable trailer tow hitch" retrofit using the Conversions path and work through the action plan created If necessary, carry out a car test using the ISTA system and note or work through any entered error memory Conduct a function test Re-assemble the car in a logical manner The sections entitled "Customer information" and "Statutory regulations pursuant to EC Directive 94/20/EC" at the end of these Installation Instructions must be printed out and given to the customer. 6/22

17 Wiring diagram 2,5 RTBL 30F_EIN 3 B-CAN_L A74*4B A5* A255*2B 4 A255*3B A8* A9* R* A255*B A255*2B A7* 0,35 BLGE A8* Z2*8B Y4* 30F_EIN 30F_AUS Y3* Y2* 46 0,75 SWGR Y* 0,35 RTGE Z2*8B A74*3B 30F_F4_HR 4 A4* 2,5 RTGE 0,75 SWGE 30F_F3_HR 5 30F_AUS Y* 3 A74*4B A2* A73 A74*3B A74 A3* O* FRA_H_R 4 Z2*3B X300*V B-CAN_H A* A2* O* F20 F4 F3 2,5 RTSW Z2*3B 30F_F4_HR A0* X86*V 5 30F_F3_HR 30B_F39_HR 4 Z2*9B F20 F20 F39 Z2 BL_M B_F39_HR 3L 3L Z E* 8 7 A* Z0*9B A6* F Z Legend A* A2* A3* A4* A5* A6* A7* A8* A9* A0* A* A2* Connect SW 3-pin socket casing to socket E* Cable open, SW/GE cable, with miniature connector O* to REM A74 Cable open, SW/GR cable, with miniature connector O* to REM A74 Connect socket contact, GE/RT cable, to PIN 3 of plug A74*4B Connect socket contact, GE/BR cable, to PIN 46 of plug A74*4B Screw M6 ring eyelet, BR cable, onto ground support point Z0*9B Connect SW 24-pin socket casing to control unit R* Connect SW 6-pin socket casing to control unit R* Connect SW 0-pin socket casing to control unit R* Connect socket contact, RT/SW cable, to PIN 4 of plug Z2*9B Connect socket contact, RT/BL cable, to PIN 5 of plug Z2*3B Connect socket contact, RT/GE cable, to PIN 4 of plug Z2*3B Y* Y2* Y3* Y4* Connect socket contact, RT/GE cable, to PIN 5 of plug A73*3B Connect socket contact, BL/GE cable, to PIN 4 of plug A73*3B Connect socket contact, RT/GE cable, to PIN of plug Z2*8B Connect socket contact, BL/GE cable, to PIN 3 of plug Z2*8B 7/22

18 9. Wiring diagram Legend E* O* R* Y* Socket Miniature connector Control unit Auxiliary cable A73 A74 Z2 FEM REM Rear fuse box A73*3B A74*4B A255*B A255*2B A255*3B Z2*8B Z2*9B Z2*3B SW 54-pin socket casing on FEM A73 SW 54-pin socket casing on REM A74 SW 24-pin socket casing A7 SW 6-pin socket casing A8* SW 0-pin socket casing A9* GR 6+6-pin socket casing SW 7-pin socket casing VI 7-pin socket casing All the designations marked with an asterisk (*) apply only to these installation instructions or this wiring diagram. Cable colours BL Blue BO Bordeaux (Burgundy) BR Brown GE Yellow GN Green GR L-GN NT OR RO Grey Light green Natural Orange Pink RT SW TR VI WS Red Black Transparent Violet White 8/22

19 0. Customer information Remove the ball head () when not in use and store it in the storage bag (2). 2 Always keep the ball head () in the storage bag (2) in the lower loadspace floor of your car. /2 F Z 9/22

20 . Statutory regulations pursuant to EC Directive 94/20/EC Appendix VII Regulations for the homologation of a vehicle for the optional installation of mechanical connection devices (trailer tow hitches). General regulations. The vehicle manufacturer determines which types and classes of connecting devices can be fitted onto the vehicle type, and specifies the values D, V, S or U (if applicable) which are based on the design of the vehicle type in combination with the planned type of connecting devices. The code values D, V, S or U of the connecting devices approved in accordance with this directive must be greater than or equal to those specified for the vehicle type in question..2 The connection devices must be installed on the vehicle type in accordance with the installation instructions specified by the vehicle manufacturer and in compliance with the manufacturer of the connection device and the Technical Service. The vehicle manufacturer shall define the permitted points for securing the connection devices to the vehicle type and, if necessary, the mountings, installation plates, etc. that must be mounted on this specific vehicle type..3 Only automatic hitches are allowed to be used for hitching up trailers with a total mass of more than 3.5 tonnes to motor vehicles; these automatic hitches must permit an automatic hitching procedure..4 When connecting devices of class B, D, E and H are fitted to trailers, it is always necessary to assume a value of 32 tonnes for the total mass T of the towing vehicle in order to calculate the D value. If the D value of the connecting device for T = 32 tonnes is not sufficient, the resultant restriction relating to the mass T of the towing vehicle and the mass of the vehicle combination (towing vehicle and trailer) must be specified in the approval sheet for the trailer. The V value must only be specified for vehicles with a technical gross weight in excess of 3.5 tonnes. 20/22

21 . Statutory regulations pursuant to EC Directive 94/20/EC 2. Special regulations 2. Fitting coupling balls and towing brackets (ball head with coupling device) 2.. When coupling balls with holders are fitted to a vehicle type of class M, class M2 below 3.5 tonnes and class N, the clearance and height dimensions shown in the figure and 2 must be maintained. This requirement does not apply to off-road vehicles in the sense of Appendix II of Directive 92/53/EEC. Unspecified details are to be selected to suit the appropriate purpose. The dimensions and angles must be checked using suitable measuring instruments The vehicle manufacturer must supply installation instructions for coupling balls and towing brackets. These installation instructions must specify whether the attachment area requires reinforcing It must also be possible to couple and uncouple coupling heads when the longitudinal axis of the coupling head in relation to the centre line of the coupling ball and towing bracket: a) is turned horizontally b = 60 to the right or left (see Figure 2), b) is turned vertically a = 0 upwards or downwards (see Figure ), c) is rotated axially through 0 to the right or left The mounted coupling ball must not obscure the rear registration plate or the space provided for the rear registration plate; otherwise, a ball that can be removed without requiring special tools must be used. 2.2 Installing towing ball couplings 2.2. Class B coupling heads are permitted to be used with trailers of a gross mass up to 3.5 tonnes. Tow ball head couplings must be installed in such a way that the coupling point of the trailer - when the trailer is horizontal and with a permitted axle load - is 430 mm ± 35 mm above the horizontal wheel contact level (see Figure 3). The horizontal position for caravans and trailers is the position in which the floor or the loading bed is horizontal. In the case of trailers without such a reference plane (e.g. boat trailers and the like), the manufacturer must specify a suitable reference line for defining the horizontal position. The required height only applies to trailers that are to be coupled to the vehicles listed in It must be possible to operate coupling heads safely within the clearance of the coupling ball as shown in figures and 2. 2/22

22 . Statutory regulations pursuant to EC Directive 94/20/EC Figure Space for coupling ball, side view. 00 max. B B 65 min. a 55 min. 32 min. a min. 45 max. 45 min. 45 max Z Figure 2 75 min. 75 min. 30 max. A 30 max. 30 max. R 30 max. Space for coupling ball, plan view. b m 4.5 R4. ax 0 ma ax. b Z Figure 3 (430 ± 35) mm Installation height for the towing ball coupling Z 22/22