Original BMW Accessories. Installation Instructions.

Transcription

1 Original BMW ccessories. Installation Instructions. Removable trailer tow hitch retrofit BMW X5 (F15) BMW X5 M (F85) BMW X6 (F16) BMW X6 M (F86) Installation instructions not valid for cars with S 791 and edrive cars (plug-in hybrid) Installation instructions not valid for cars with N63N/S63R engine with S 496, S 536, S 601, S6 FH. Retrofit kit number Electrical components retrofit kit Trailer tow hitch removable Installation time The installation time is approx. 4.0 hours. This may vary depending on the condition of the vehicle and the equipment in it. The fan frame and fan will need to be replaced on certain models of vehicle. The installation time in this case will increase by around 1.5 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. ll 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 1.0 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 ftersales ssistance Portal (SP). Quote the following information: Chassis number, Retrofit kit part number, detailed description of the problem, and the steps already taken. Do not archive the hard copy of these installation instructions since daily updates are made via SP! BMW G, Munich /2014 (Z/Z) 2.1 1/19

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. Installation information! The fan frame and fan will need to be replaced on certain models of vehicle. If you do not replace the electric fan, the towing capacity will be reduced and the engine may stop. 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 G. dditional 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. ll pictures show LHD cars; proceed accordingly on RHD cars. fter the installation work, the retrofit must be programmed / coded via the Conversions path. Ordering instructions G control unit C is not included in the retrofit kit and must be ordered separately (see EPC for part number and further details). Legal requirements type approval in accordance with EC Directive 94/20/EC ppendix VII exists for the trailer tow hitch, with EC homologation marke7*55r* If you comply with these regulations and notes in these installation instructions, no special acceptance test pursuant to 19 of the German Road Traffic Licensing Directive and no special entry in the vehicle registration document is necessary. List of special equipment The following special equipment must be taken into consideration when installing: S 791 S 536 S 496 S 601 S 6FH Coolbox uxiliary heater Heated rear seat TV function Rear seat entertainment Information for the customer The section on "Statutory regulations pursuant to EC Directive 94/20/EC" at the end of the Installation Instructions must be printed out and handed to the customer. Special tools required Details of the special tool required can be found in the relevant IST repair manual. BMW G, Munich /2014 (Z/Z) 2.1 2/19

3 Section Page 1. Repinning Parts list Preparatory work Retrofit wiring diagram connection diagram Installation and cabling diagram Installing the trailer tow hitch, routing and connecting the retrofit wiring harness Concluding work and coding Wiring diagram Statutory regulations pursuant to EC Directive 94/20/EC BMW G, Munich /2014 (Z/Z) 2.1 3/19

4 1. Repinning Incorrect pinning causes failure of power supply to rear lights. Incorrect pinning of the socket I , which is a component of the retrofit cable harness The socket with part number is not affected by this measure. In order to correct the pinning, the following parts are to be ordered separately: Quantity Part number Description Pin contact MQS EL Spade contact Protective sleeve Protective sleeve 50 cm no partnumber 0.5 mm² cable 269*1B 1* 268*1B 2* 269*1B 1* 268*1B 2* SENSOR SENSOR 0,5 SWGN 0,5 SWGN I* I* F Z The drawing on the left shows the incorrectly pinned socket. The drawing on the right shows the correctly pinned socket. Change pin assignments on 6-pin connector as follows: Cable RTSW from PIN 3 to PIN 2 Cable BR from PIN 5 to PIN1 On 12-pin connector proceed as follows: Disconnect cable SWGN from PIN 9 and PIN 10 and remove (no longer required) Insert jumper cable as follows: Using the material ordered separately, lay a new jumper cable from the 6-pin connector PIN 6 to the 12-pin connector PIN 11 BMW G, Munich /2014 (Z/Z) 2.1 4/19

5 2. Parts list B C D E F G H I J K L M N O P Q R F Z Legend Retrofit wiring harness B Trailer tow hitch C G control unit (not supplied in the retrofit kit) D M12 hexagon nut (4 x) E Cable tie (30 x) F Cable tie with holder (2 units, 1 unit is required) G Cable tie with holder (not required) H Cable tie with holder I Socket J Fuse 20 K Fuse 30 (3 x) L SW 7-pin socket casing M VI 7-pin socket casing N BL 7-pin socket casing O Expanding rivet (6 x) P Pan head screw (3 x) Q Storage fixture R Seal (2x) BMW G, Munich /2014 (Z/Z) 2.1 5/19

6 3. Preparatory work IST 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) Flap in the luggage compartment trim on the right Storage compartment in the luggage compartment on the right Release the rear fuse holder Luggage compartment wheel arch trim, right Rear seat backrest side section, right Rear right door sill cover strip (interior) Trim for right door pillar (bottom) Front right door sill cover strip (interior) Side footwell trim on right pillar Only cars with basic seats Rear seat BMW G, Munich /2014 (Z/Z) 2.1 6/19

7 4. Retrofit wiring diagram connection diagram F Z Item Designation Signal Cable colour/ cross-section Connection location in the car bbreviation/ slot Retrofit wiring harness SW 12-pin socket casing To socket I X269*1B 2 SW 6-pin socket casing To socket I X268*1B 3 Socket contact Terminal 30B 4 Socket contact Terminal 30F 5 Socket contact Terminal 30F 6 Socket contact Terminal 30B RT/SW 2.5 mm² RT/GE 2.5 mm² RT/VI 2.5 mm² RT/BL 2.5 mm² To rear right power distribution box Z2 To rear right power distribution box Z2 To rear right power distribution box Z2 To rear right power distribution box Z2 Z2*9B PIN 4 Z2*13B PIN 4 Z2*13B PIN 5 Z2*11B PIN 4 7 GR 10-pin socket casing To G control unit C 255*4B 8 SW 10-pin socket casing To G control unit C 255*3B 9 SW 24-pin socket casing To G control unit C 255*1B 10 SW 6-pin socket casing To G control unit C 255*2B 11 Socket contact B-CN_H GE/RT 0.35 mm² 12 Socket contact B-CN_L GE/BR 0.35 mm² 13 M6 ring eyelet Terminal 31 BR 2.50 mm² To terminating resistor plug R2 To terminating resistor plug R2 To ground support point, right-hand rear wheel arch 14 NT 6-pin socket casing Insulate and tie back Socket contact BL_SH SW/GE 0.35 mm² 16 Socket contact WBL SW/GR 0.35 mm² To body domain controller plug 258 To body domain controller plug 258 R2*1B PIN 8 R2*1B PIN 21 Z10*14B 258*3B PIN *3B PIN 17 BMW G, Munich /2014 (Z/Z) 2.1 7/19

8 5. Installation and cabling diagram C 2 1 I 5* C I Retrofit wiring harness G control unit Socket F Z 1 Rubber grommet 2 Rear right power distribution box Z2, plugs Z2*9B, Z2*11B, Z2*13B 3 Terminating resistor R2, plug R2*1B 4 Ground support point Z10*14B 5 Body Domain Controller 258, plug 258*3B for LHD vehicles 5* Body Domain Controller 258, plug 258*3B for RHD vehicles BMW G, Munich /2014 (Z/Z) 2.1 8/19

9 6. Installing the trailer tow hitch, routing and connecting the retrofit wiring harness 1 R 2 Removal of the existing seal (1) is only shown on the right-hand side of the car; proceed in the same way on the left-hand side of the car. Remove existing seal (1) on left and right and replace with seal R. Remove the sealing cover (2) (it is no longer required). F Z Route the branches 1-2 of the retrofit cable harness through opening (1) from inside to outside F Z D D! Note the tightening torque value: 108 Nm. Bolt trailer tow hitch B into place using hexagon nuts D. D B D F Z F H! Route retrofit wiring harness so that it never touches any parts of the exhaust system. Secure retrofit cable harness using cable ties F and H. F Z BMW G, Munich /2014 (Z/Z) 2.1 9/19

10 6. Installing the trailer tow hitch, routing and connecting the retrofit wiring harness I Mount socket I on trailer tow hitch using pan-head screws P. Connect branches 1-2 of the retrofit cable harness to branches (1) and (2) of socket I. 1 P F Z Secure cables of the socket I and of the retrofit cable harness to trailer tow hitch using cable ties E. I E F Z BMW G, Munich /2014 (Z/Z) /19

11 6. Installing the trailer tow hitch, routing and connecting the retrofit wiring harness Z E Z10*14B Connect retrofit wiring harness as follows: Branches 3 6 to rear power distribution box Z2 Branches 7-10 to the installation point of the control unit holder Branches behind rear right power distribution box Z2 Branch 13 to ground support point Z10*14B Insulate and tie back branch 14 (not required). Branches to the installation point of the BDC on the right -pillar Secure retrofit wiring harness at suitable points using cable ties E. F Z BMW G, Munich /2014 (Z/Z) /19

12 6. Installing the trailer tow hitch, routing and connecting the retrofit wiring harness Z2*13B Z2 Z2*9B 3 6 Fuses can fall out when connecting plugs to rear right power distribution box Z2. Ensure that all the fuses are replaced in their correct slots. If plugs Z2*9B, Z2*13B or Z2*11B are not present, use socket casing L, M and N. Route branches 3-6 along the standard wiring harness to rear right power distribution box Z2 and connect as follows: Connect branch 3, RT/SW cable, to plug Z2*9B, SW 7-pin socket casing, PIN 4 Z2*11B F Z Connect branch 4, RT/GE cable, to plug Z2*13B, VI 7-pin socket casing, PIN 4 Connect branch 5, RT/VI cable, to plug Z2*13B, VI 7-pin socket casing, PIN 5 Connect branch 6, RT/BL cable, to plug Z2*11B, BL 7-pin socket casing, PIN 4 F139 F113 Z2 F114 J/K If slots F113, F114, F139 and F163 are already occupied by fuses, fuses J and K are not required. Insert fuses J and K as follows into rear right power distribution box Z2: 20 fuse J in slot F fuses K in slots F113, F114 and F163 F163 F Z Insert G control unit C in the control unit holder. Route branches 7-10 to G control unit C and connect C F Z BMW G, Munich /2014 (Z/Z) /19

13 6. Installing the trailer tow hitch, routing and connecting the retrofit wiring harness R2*1B Route branches to terminating resistor R2 and connect as follows: Branch 11, GE/RT cable, to PIN 8 Branch 12, GE/BR cable, to PIN 21 R F Z 13 Screw on branch 13, M6 ring eyelet, to ground support point Z10*14B. Z10*14B F Z 258*3B 258 Route branches to body domain controller 258 and connect as follows: Connect branch 15, SW/GE cable, to PIN 16 of plug 258*3B Connect branch 16, SW/GR cable, to PIN 17 of plug 258*3B F Z 1 Q Ensure that the contents of the storage fixture are complete. ttach storage fixture Q using existing screws (1). F Z BMW G, Munich /2014 (Z/Z) /19

14 7. Concluding work and coding The retrofit system requires programming / coding. Expanding rivets O are required to secure the rear bumper trim to the wheel arches Connect the battery Connect the battery charger to the car Connect the car to the IST workshop system Call up the IST/P car programming facility If using IST/P, please note the instructions provided in the IST/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 IST system and note or work through any entered error memory BMW G, Munich /2014 (Z/Z) /19

15 8. Wiring diagram Z2 Z2 Z2 F139 F114 F113 F R2 30F_F139_HR Z2*9B 3* 2.5 RTSW 30F_F114_HR 30F_F114_HR Z1*13B 4* 2.5 RTGE 30F_F113_HR 30F_F113_HR Z2*13B 5* 2.5 RTVI 30B_F163_HR 30B_F163_HR Z2*11B 6* 2.5 RTBL 255*2B 10* 258*3B 15* BL_SH BL_SH WBL 0.35 SWGE WBL 0.35 SWGR 258*3B 16* R2*1B 11* 8 21 R2*1B 12* 255*3B 8* C* 268*1B 2* 30F_F139_HR 2.5 WSRT 2.5 BLBR SENSOR_GND SENSOR_GND BR HLL+ HLL+ 6 S_SICH_ WSGN 10 S_SICH_ GNVI SWWS I* I* 5 E E WS 8 S_SICH_1 S_SICH_ GE GRRT 2 58R 58R GNRT 4 49R 49R GEBL 3 RS RS GRSW 7 58L 58L BLGE 6 49L 49L BLRT 1 HLLSENSOR HLLSENSOR WSGE 9 255*1B 9* 269*1B 1* 255*2B 10* Z10*14B 13* F Z Legend 1* SW 12-pin socket casing, plug X269*1B, to socket I* 2* SW 6-pin socket casing, plug X268*1B, to socket I* 3* Socket contact, RT/SW cable, to plug Z2*9B of power distribution box Z2 4* Socket contact, RT/GE cable, to plug Z2*13B of power distribution box Z2 5* Socket contact, RT/VI cable, to plug Z2*13B of power distribution box Z2 6* Socket contact, RT/BL cable, to plug Z2*11B of power distribution box Z2 7* GR 10-pin socket casing, to G control unit C* 8* SW 10-pin socket casing, to G control unit C* 9* SW 24-pin socket casing, to G control unit C* 10* SW 6-pin socket casing, to G control unit C* 11* Socket contact, GE/RT cable, to plug R2*1B of terminating resistor R2 12* Socket contact, GE/BR cable, to plug R2*1B of terminating resistor R2 13* M6 ring eyelet, to ground connection Z10*14B 14* NT 6-pin socket casing, insulate and tie back 15* Socket contact, SW/GE cable, to plug 258*3B of BDC * Socket contact, SW/GR cable, to plug 258*3B of BDC 258 BMW G, Munich /2014 (Z/Z) /19

16 8. Wiring diagram Legend I* Socket C* G control unit 258 R2 Z2 Body Domain Controller (BDC) Terminating resistor Rear right power distribution box 258*3B SW 54-pin socket casing, BDC 258 R2*1B SW 12-pin socket casing, terminating resistor R2 Z2*9B SW 7-pin socket casing, to rear right power distribution box Z2 Z2*11B BL 7-pin socket casing, to rear right power distribution box Z2 Z2*13B VI 7-pin socket casing, to rear right power distribution box Z2 Z10*14B Ground support point, to rear right wheel arch ll the designations marked with an asterisk (*) apply only to these installation instructions or this wiring diagram. Cable colours BL Blue GR Grey RT Red BO Bordeaux (Burgundy) L-GN Light green SW Black BR Brown NT Natural TR Transparent GE Yellow OR Orange VI Violet GN Green RO Pink WS White BMW G, Munich /2014 (Z/Z) /19

17 9. Statutory regulations pursuant to EC Directive 94/20/EC ppendix VII Regulations for the homologation of a vehicle for the optional installation of mechanical connection devices (trailer tow hitches) 1. General regulations 1.1 The vehicle manufacturer determines which types and classes of connecting devices can be fitted onto the vehicle type, and specifies the values D, V1, 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. 1.2 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. 1.3 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. 1.4 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. 1 1 The V value must only be specified for vehicles with a technical gross weight in excess of 3.5 tonnes. BMW G, Munich /2014 (Z/Z) /19

18 9. Statutory regulations pursuant to EC Directive 94/20/EC 2. Special regulations 2.1 Fitting coupling balls and towing brackets (ball head with coupling device) When coupling balls with holders are fitted to a vehicle type of class M1, class M2 below 3.5 tonnes or class N1, the clearance and height dimensions shown in figures 1 and 2 must be maintained. This requirement does not apply to off-road vehicles in the sense of ppendix 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 = 10 upwards or downwards (see Figure 1), c) is rotated axially through 10 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 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. On trailers without a reference area of this type (for example boat trailers or the like) the manufacturer of the trailer must specify a suitable reference line to define 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 1 and 2 BMW G, Munich /2014 (Z/Z) /19

19 9. Statutory regulations pursuant to EC Directive 94/20/EC 45 max. Figure 1 Space for coupling ball, side view. B 100 max. B 140 min. 65 min. 55 min. 32 min. 45 max. a 45 min. a Z Figure 2 30 max. 75 min. 75 min. 30 max. 30 max. R 14.5 max. R 40 max. b Space for coupling ball, plan view. 30 max. b Z Figure 3 Installation height for the towing ball coupling. (430 ± 35) mm Z BMW G, Munich /2014 (Z/Z) /19