ORIGINL MINI SSORIS. INSTLLTION INSTRUTIONS. dditional Headlight Retrofit MINI (F56) Retrofit kit number 63 0 40 9 63 0 47 669 63 355 766 63 84 9 dditional headlight retrofit kit, black dditional headlight retrofit kit, chrome dditional headlight bracket Interface add-on kit (only for cars with S 5 or S 54) Installation time The installation time is appro..5 hours. This may vary depending on the condition of the car and the equipment in it. Important information These installation instructions are primarily designed for use within the MINI dealership organisation and by authorised MINI service companies. In any event the target group for these installation instructions is specialist personnel trained on MINI cars with the appropriate specialist knowledge. ll work must be completed using the latest MINI repair manuals, circuit 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 eperience installation or function problems, restrict troubleshooting to appro. 0.5 hours for mechanical work and.0 hour for electrical work. To avoid unnecessary etra work and/or costs, an inquiry is to be sent straight away to the technical parts support via the ftersales ssistance Portal (SP). Quote the following information: hassis number, Retrofit kit part number, detailed description of the problem, ny work already carried out. Do not archive the hard copy of these installation instructions since daily updates are provided via SP! 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 tet. 0 9 88 586 0/04 /9
Installation information nsure that the cables and/or lines are not kinked or damaged as you install them in the car. osts arising from this will not be reimbursed by BMW G. dditional cables/lines 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. fter installation, the additional headlights must be adjusted. Note the SD guidelines. ustomer information Print out the ustomer information section at the end of these installation instructions and give it to the customer. List of special equipment The following special equipment must be taken into consideration when installing: S 5 S 54 LD headlight LD headlight with cornering light Special tools required Details of the special tool required can be found in the relevant IST repair manual. 0 9 88 586 0/04 /9
Section Page. Parts list for retrofit kit........................................................................ 4. Preparatory work.............................................................................. 5 3. Retrofit wiring harness connection diagram.................................................... 6 4. Installation and cabling diagram for LHD cars.................................................. 7 5. Installation and cabling diagram for RHD cars.................................................. 8 6. Routing and connecting the retrofit wiring harness............................................. 9 7. Working with the bumper trim and installing the additional headlight........................... 8. oncluding work and coding.................................................................. 4 9. Wiring diagram................................................................................ 5 0. ustomer information......................................................................... 7 0 9 88 586 0/04 3/9
. Parts list for retrofit kit B D F G H I MINI K J R L S N M T O P Q U F56 0077 Z Legend B D F G H I J K L M N O P Q R S T U Retrofit wiring harness (part of the additional headlight retrofit kit) ontrol module (part of the additional headlight retrofit kit) dditional headlight (, part of the additional headlight retrofit kit) SW -pin pin housing (, part of the additional headlight retrofit kit) Left additional headlight bracket (part of the additional headlight bracket retrofit kit) Right additional headlight bracket (part of the additional headlight bracket retrofit kit) Pan head screw (, part of the additional headlight bracket retrofit kit) Rivet nut (, part of the additional headlight bracket retrofit kit) Spring washer D = 6.4 mm (4, part of the additional headlight bracket retrofit kit) Spring washer D = 5.3 mm (, part of the additional headlight bracket retrofit kit) Screw M66 (4, part of the additional headlight bracket retrofit kit) Screw M5 (4, part of the additional headlight bracket retrofit kit) Interface (only for cars with S 5 or S 54, part of the interface add-on kit) Wiring harness interface (only for cars with S 5 or S 54, part of the interface add-on kit) Miniature connector (4, only for cars with S 5 or S 54, part of the interface add-on kit) over cap (only for cars with S 5 or S 54, part of the interface add-on kit) Bracket lower section (, part of the additional headlight bracket retrofit kit) Socket contact (only for cars with S 5 or S 54, part of the interface add-on kit) -way miniature connector (, part of the additional headlight retrofit kit) 5-way miniature connector (part of the additional headlight retrofit kit, not required) SW -pin socket casing (, part of the additional headlight retrofit kit) 0 9 88 586 0/04 4/9
. Preparatory work IST No. Disconnect the negative battery cable 6 0 900 The following components must be removed first of all Front bumper trim 5... owl cover (Interior) door sill cover strip, passenger side 5 47 000 Footwell side trim on the -pillar, passenger side 5 43 075 Glove compartment 0 9 88 586 0/04 5/9
3. Retrofit wiring harness connection diagram 4 3 9 N N 5 7 6 8 N4 N5 N N3 Item Designation Signal able colour / cross-section F56 0079 Z onnection location in the car bbreviation/ slot Retrofit wiring harness Socket contact FSL BL/RT.0 mm² With socket casing U to pin housing D of lefthand additional headlight PIN Socket contact Terminal 3 BR.0 mm² With socket casing U to pin housing D of lefthand additional headlight PIN 3 Socket contact FSR BL/WS.0 mm² With socket casing U to pin housing D of right-hand additional headlight PIN 4 Socket contact Terminal 3 BR.0 mm² With socket casing U to pin housing D of right-hand additional headlight PIN 5 M6 ring eyelet Terminal 3 BR Screw onto ground support point net to DS unit Z0*B 6 M8 ring eyelet Terminal 30 RT/BL.5 mm² To terminal 30 support point on fuse holder in the interior 7 Fuse holder 8 SW 9-pin relay base 9 Open cable Terminal 56a G/BL 0.75 mm² To control module B Only cars without S 5 or S 54 With miniature connector S to the cable from the BD 58*3B PIN 34 N PIN 6 Only cars with S 5 or S 54 With socket contact R in branch N N Wiring harness interface Only cars with S 5 or S 54 N SW -pin socket casing To interface M N Twisted cable N High GN/BL 0.35 mm² With miniature connector O to the cable from the BD 58*8B PIN 44 N3 Twisted cable N Low GN 0.35 mm² With miniature connector O to the cable from the BD 58*8B PIN 43 N4 Open cable Terminal 5 RT 0.35 mm² With miniature connector O to the cable from the BD 58*3B PIN 0 N5 Open cable Terminal 3 BR 0.35 mm² With miniature connector O to the cable from the BD 58*3B PIN 4 0 9 88 586 0/04 6/9
4. Installation and cabling diagram for LHD cars 3 4 F56 0078 Z Retrofit wiring harness dditional headlight 3 4 Ground support point Z0*B Rubber grommet Body Domain ontroller (BD) 58 Power distribution bo in the interior compartment 0 9 88 586 0/04 7/9
5. Installation and cabling diagram for RHD cars 4 3 F56 0089 Z Retrofit wiring harness dditional headlight 3 4 Negative terminal on the car battery Rubber grommet Body Domain ontroller (BD) 58 Power distribution bo in the interior compartment 0 9 88 586 0/04 8/9
6. Routing and connecting the retrofit wiring harness Unscrew the screws () on the reinforcing strut (). Place additional headlight bracket and F on top and screw on using screw () (do not tighten fully). F F56 005 Z Draw on a dimension 3 mm from the edge () on the bumper trim support (). Push additional headlight bracket and F over the cut-out line and draw on the drilling points (3). 3 mm Remove additional headlight holder and F. 3 F F56 0030 Z Drill through the holes () with a 9. mm diameter drill bit. H Insert rivet nuts H into the holes (). F56 003 Z Screw on additional headlight holder and F using pan head screws G and original screws (). G F F56 003 Z 0 9 88 586 0/04 9/9
6. Routing and connecting the retrofit wiring harness Wind up the cable around branch 5 and 6 of retrofit wiring harness. Wrap branch 5 and 6 individually using suitable insulating tape. 6 5 F56 0080 Z 5-9 Route retrofit wiring harness as follows: Branches - to the left additional headlight Branches 3-4 to the right additional headlight Branches 5-9 to the installation point of the DS unit Secure retrofit wiring harness using usual workshop cable ties () to the reinforcing strut (). 3-4 - F56 0080 Z On RHD cars, screw branch 5 to the negative terminal of the car battery. 6-9 To ensure a good ground connection, remove any paint from ground support point Z0*B. Z0*B Screw branch 5 onto ground support point Z0*0B. 5 Route branches 6-9 through the rubber grommet () into the interior of the car. F56 06 Z Release the fuse bo () and place it to one side. Screw on branch 6 to the screw-on clamp of the fuse bo (). 7 Secure fuse holder 7 in the area of the fuse bo () using conventional cable ties. 6 F56 0034 Z 0 9 88 586 0/04 0/9
6. Routing and connecting the retrofit wiring harness onnect control module B to branch 8. B Secure branch 8 using suitable cable ties in the area of BD 58. 58 8 F56 0054 Z 58 S Only cars without S 5 or S 54 onnect branch 9 as follows to BD 58: onnect branch 9, G/BL cable, with miniature connector S to the cable from PIN 34 of plug 58*3B 58*3B 9 F56 0083 Z 58*8B Only cars with S 5 or S 54 onnect wiring harness interface N as follows to BD 58: 58 Branch N, GN/BL cable, with miniature connector O to the cable from PIN 44 of plug 58*8B N N4-N5 58*3B Branch N3, GN cable, with miniature connector O to the cable from PIN 43 of plug 58*8B Branch N4, RT cable, with miniature connector O to the cable from PIN 0 of plug 58*3B O N-N3 F56 0064 Z Branch N5, BR cable, with miniature connector O to the cable from PIN 4 of plug 58*3B onnect branch 9, G/BL cable, to PIN 6 of socket casing N. M Push cover cap P onto branch N. R onnect branch N to interface M. N/P Secure interface M at a suitable point. 9 F56 0084 Z 0 9 88 586 0/04 /9
7. Working with the bumper trim and installing the additional headlight Danger of damage! Take etra care when working with the bumper trim (3). Trim any ecess () on openings () in the bumper trim (3) using a suitable tool. 3 F56 0044 Z Push bumper trim () over additional headlight bracket but do not secure into place yet. F56 0075 Z The installation steps are shown only on the left-hand side of the car, proceed in the same way on the right-hand side of the car. L J Screw bracket lower section Q using spring washer J and screw L onto additional headlight bracket. Q F56 0085 Z 0 9 88 586 0/04 /9
7. Working with the bumper trim and installing the additional headlight - U D sk a second person to assist you with this step. Hold additional headlight against additional headlight bracket but do not secure in place yet. Route branches - below additional headlight bracket through the ornamental grille on the front bumper trim to socket casing U. onnect branches - as follows to socket casing U: Branch, BL/RT cable, to PIN F56 0087 Z Branch, BR cable, to PIN onnect cables from additional headlight to pin housing D as follows: VI/SW cable to PIN BR cable to PIN sk a second person to assist you with this step. U 3-4 Hold additional headlight against additional headlight bracket but do not secure in place yet. Route branches 3-4 below additional headlight bracket through the ornamental grille on the front bumper trim to socket casing U. D onnect branches 3-4 as follows to socket casing U: Branch 3, BL/WS cable, to PIN F56 0070 Z Branch 4, BR cable, to PIN onnect cables from additional headlight to pin housing D as follows: VI/SW cable to PIN BR cable to PIN The installation steps are shown only on the left-hand side of the car, proceed in the same way on the right-hand side of the car. The tightening torque for screws K is Nm. Secure the bumper trim. Place additional headlight on additional headlight bracket and screw on using spring washers I and screws K. I/K F56 006 Z 0 9 88 586 0/04 3/9
8. oncluding work and coding The retrofit system does not require programming / coding. onnect the battery onduct a function test Re-assemble the car in a logical manner Give the installation information to the customer The tightening torque for screws () and K is Nm. djust additional headlight as follows with the headlight adjustment tool: MINI Vertical adjustment Loosen the screw () and adjust the vertical setting Horizontal adjustment Loosen both screws K and adjust the horizontal setting K F56 0067 Z 0 9 88 586 0/04 4/9
9. Wiring diagram B* 8 FSL 6 Tl. 3 FSR 4 56a 8*.0 BR.5 RT 5 Tl. 30.0 BR 0.75 G/BL.0 BL/WS 3* 4* U* D* 5* 9*.5 G/BL.0 BR Z.0 BL/RT 6* * * U* D*.0 BL/WS.0 BR.5 RT/BL.0 BR 5 7*.0 BL/RT 58 58*8B M Legend * * 3* 4* 5* 6* 7* 8* 9* Socket contact, BL/RT cable Socket contact, BR cable Socket contact, BL/WS cable Socket contact, BR cable M6 ring eyelet, BR cable M8 ring eyelet, RT/BL cable Fuse holder SW 9-pin relay base Open cable, G/BL cable N* N* N3* N4* N5* SW -pin socket casing Open cable, GN/BL cable Open cable, GN cable Open cable, RT cable Open cable, BR cable B* * D* M* O* S* U* ontrol module dditional headlight SW -pin pin housing Interface (only cars with S 5 or S 54) Miniature connector (only cars with S 5 or S 54) Miniature connector SW -pin socket casing 0 9 88 586 Tl. 5 N-L 0/04 58*3B O* N4* 0.35 BR 0.35 GN N-H O* N3* 4 0.35 BRSW O* N3* 0.35 GNGR O* N* 0 0.35 RT 43 Tl. 56a 6 Tl. 56a 34 44 0.35 GNBL * 0.75 G/BL * 58*3B Tl. 3 N* F 560086 Z 5/9
9. Wiring diagram 58 58*3B 58*8B Z Z0*B Body Domain ontroller BD SW 54-pin socket casing SW 54-pin socket casing Power distribution bo in the interior compartment Ground support point in the engine compartment ll the designations marked with an asterisk (*) apply only to these installation instructions or this wiring diagram. able colours BL Blue BO Bordeau (Burgundy) BR Brown G Yellow GN Green GR L-GN NT OR RO 0 9 88 586 Grey Light green Natural Orange Pink RT SW TR VI WS 0/04 Red Black Transparent Violet White 6/9
0. ustomer information planation of 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 tet. onsult the applicable state and regional laws governing the use of additional headlights. Some countries, for instance, forbid the simultaneous use of four lights, while others ban their use on public roads altogether and require that the additional headlights are equipped with optional headlight covers when not in use. Operating the additional headlights Once activated, the additional headlights light up automatically when the headlights or headlight flash are switched on. Whenever you turn the ignition off/on, you must re-activate the additional headlights. Switching the additional headlights on Switch on the ignition or start the engine Switch the headlights on or actuate the headlight flash The additional headlights light up along with the headlights or headlight flash Switching the additional headlights off Switch off the headlights. 0 9 88 586 0/04 7/9
0. ustomer information hanging the bulb Lamps and lights are an important part of the car's safety features. ppropriate care should therefore be used when handling them. If you are not familiar with such work, have it performed by your MINI service centre. Bulb required: H3 (55 W). Do not touch the glass rounded section of the bulb with your bare hands, since even slight contamination can burn onto the surface and reduce the bulb's service life. Use a clean cloth, a paper towel or similar to take hold of the bulb at its base.! When carrying out any work on the car's electrical system, switch off the device you are working on or disconnect the battery's negative terminal, otherwise you may cause a short-circuit. lways read any instructions provided by the bulb's manufacturer in order to avoid injury and/or damage when changing the bulb. Unscrew both screws () and pull the additional headlight () carefully forwards. MINI R56 0 Z In order to avoid damaging the cable (), hold the additional headlight () with one hand. Unscrew the llen screw (3) and remove the housing (4). 3 4 R56 04 Z The tightening torque for the screws is Nm. The position of the additional headlight must be adjusted after the bulb has been changed. Remove the rubber cap () and disconnect the plug (). 4 3 Loosen the screw (3), remove it and change the bulb (4). The headlight is reassembled in the reverse order. R56 05 Z 0 9 88 586 0/04 8/9
0. ustomer information djusting the additional headlights Have the additional headlights adjusted by your MINI dealer. If you are unable to visit your MINI dealer, you can temporarily adjust the additional headlights yourself even without the headlight adjusting tool. The steps for how to do this are described using the eample of the left-hand additional headlight. The right-hand additional headlight is adjusted in eactly the same way. To adjust the headlights, park your unladen car on even ground and around 5-0 m perpendicularly to a vertical wall. Testing the vertical setting The tightening torque for the screw () is Nm. MINI a a 5-0 m R56 08 Z Measure the distance a from the centre of the cone of light on the wall to the etension of the vehicle's longitudinal ais () Measure the distance a from the centre of the cone of light on the wall to the etension of the vehicle's longitudinal ais () If distances a and a are not identical, adjust the vertical position as follows: djusting the vertical position Loosen the screw () and rotate the additional headlight so that distances a and a are the same Tighten the screw () to Nm Testing the horizontal setting The tightening torque for the screw () is Nm. MINI Measure the height h from the centre of the additional headlight to the floor Measure the height h from the centre of the cone of light on the wall to the floor h h If heights h and h are not identical, adjust the horizontal position as follows: 5-0 m R56 07 Z djusting the horizontal position Loosen both screws () and rotate the additional headlights so that heights h and h are the same Tighten the screws () to Nm leaning and care Use a soft damp cloth to clean the additional headlights. Do not use abrasive or corrosive cleaning agents. 0 9 88 586 0/04 9/9