BMW Parts and Accessories Installation Instructions F 53 039 EVA Additional headlights on roof BMW X5 (E 53) Installation time approx. 4 hours. Installation time can vary according to the condition and fittings of the vehicle. Retrofit/Installation Kit no. 8 44 0 007 47 Retrofit/Installation Kit no. 8 44 0 007 47 Date: 03.00 Installation Instructions no. 0 9 0 38 98
Contents Chapter Page. Preparatory work on the vehicle... 3. Parts kit... 4 3. Overview of supplementary wiring harness... 6 4. Installation diagram... 7 5. Install supplementary wiring harness... 8 6. Mount roof headlights...3 7. Function test of roof headlights and adjustment of roof headlights...6 8. Paint specifications...7 9. Circuit diagram of supplementary wiring harness...8 Retrofit/Installation Kit no. 8 44 0 007 47 Date: 03.00 Installation Instructions no. 0 9 0 38 98
Important notes (Only for use within the BMW trading organisation). Installation time is approx. 6.5 hours which can vary according to the condition and fittings of the vehicle. Target Group Target group for these installation instructions are technical personnel who have been trained on BMW vehicles. All maintenance, repair, installation and resetting work should be carried out on own authority. All operations should be carried out with the aid of the current BMW - repair instructions - maintenance handbooks - job instructions in a rational sequence with the prescribed tools (special tools) whilst observing the current safety regulations. Safety instructions The supplementary wiring harness and the installation instructions are designed only for lefthand drive models. Should given PIN spaces be assigned, bridges, double crimping or parallel connections will have to be made.! Tightening torques for screw connections should be adhered to without fail. Installation notes BMW accepts no liability for damage which occurs as a result of not following the work sequence and safety instructions. In addition, any warranty claim against BMW AG is extinguished in the event of improper fitting and handling which diverges from the fitting and operating instructions. At times operations are shown as carried out on only one side of a vehicle. Operations on the other side of the vehicle should be carried out in a corresponding way. When working on the outer skin panel of the vehicle, make sure that no permanent damage occurs (scratches, pressure marks, etc). If necessary, cover sections of the vehicle outer skin panel with protective film or similar. Cable installation To avoid interference keep to the prescribed installation routes in the vehicle. Never work with so-called "Scotchlock quick connectors" as these can trigger faults in the on-board electronics. Make sure when installing cables that they do not get kinked or damaged, otherwise faults may occur which can only be localised and remedied later by extensive reworking. Costs arising in this way will not be reimbursed by BMW.! To avoid faults and short circuits by inadvertent touching of bare cable ends and by working on current-carrying cables, the battery should be disconnected before work starts. Retrofit/Installation Kit no. 8 44 0 007 47 Date: 03.00 Installation Instructions no. 0 9 0 38 98 EN/
! When working in the area of the A-pillars and the roof side-frame, care should be taken to see that the airbag is not damaged and that it is not prevented from functioning properly. Required tools and auxiliary materials Drilling machine Twist drill Ø 5 mm, Ø 0 mm Marker pen Tape measure Prick punch Hammer Unpinning tool /4 inch reversible ratchet with hexagonal insert SW 8, SW 0 Long extension Torx inserts TX-0; ZX-0,TX-40 Fork wrench SW 0 mm Torque wrench Side-cutting pliers Crimping pliers Long thin wire (length approx. 000 mm) Phillips screwdrivers, medium size Flat-tip screwdrivers, small size Zinc dust paint Loctite adhesive 70 Sikaflex 55 FC Cyanoacrylate adhesive (BMW part no. 8 9 407 43) Retrofit/Installation Kit no. 8 44 0 007 47 Date: 03.00 Installation Instructions no. 0 9 0 38 98 EN/
. Preparatory work on the vehicle TIS AW No. Disconnect battery Dismantle console at headlining, front 5 44 00 Completely dismantle roof light 63 3 000 Dismantle trim panel for roof pillar, front (A-pillar) (dismantle left and right trim panel) 5 43 0 Dismantle sun visor and hinge bracket (dismantle left and right sun visor) 5 6 080 Dismantle grab handle, front (dismantle left and right grab handle) 5 6 480 Dismantle trim panel for door pillar (bottom) (dismantle left and right door pillar) 5 43 50 Dismantle glove box 5 6 360 Remove spare wheel Dismantle flap in boot, right 5 47 7 Dismantle boot wheel-arch trim panel, right 5 47 6 Retrofit/Installation Kit no. 8 44 0 007 47 Date: 03.00 Installation Instructions no. 0 9 0 38 98 EN/3
. Parts kit a b c d e f g h i LHF RHF B Bedienungsanleitung Zusatzscheinwerfer auf Dach BMW X5 BMW Installation 5er information touring, Informations concernant le montage Montage-informatie Monteringsinformation Informazioni per il montaggio j k l m Información de montaje! The additional headlights must not be used on public roads. 0 9 0 36 4 q n o p r s F 53 069 EVA Retrofit/Installation Kit no. 8 44 0 007 47 Date: 03.00 Installation Instructions no. 0 9 0 38 98 EN/4
. Parts kit a Supplementary wiring harness b Quick connector (x) c Blade receptacle (4x) d Switch of roof headlights (x) e Frame for switch of roof headlights (x) f Front railing-foot of roof headlight, left (x) g Front railing-foot of roof headlight, right (x) h Seal moulding with through hole, left (x) i Seal moulding with through hole, right (x) j Half liner (4x) k Allen key 3 mm (x) l Instruction manual (x) Not included in the parts kit: m Headlight insert (x) n Housing (x) o Stabilising ring (x) p Rubber grommet (x) q Warning sticker (for US market only) r Special tool (opening spatula) (x) s Covering cap (x) Retrofit/Installation Kit no. 8 44 0 007 47 Date: 03.00 Installation Instructions no. 0 9 0 38 98 EN/5
3. Overview of supplementary wiring harness B C D a I H L K J G F E F 53 047 EVA Item Package / Designation Cable colour Connection point in vehicle a Supplementary wiring harness Code designation/ plug-in place B Open contacts red brown Roof headlight, left X650 C 6-pole socket housing Plug into switch of roof headlights X879 D Open contacts red brown Roof headlight, right X650 E Black relay on base (NSL module) brown/black red/green green yellow/black yellow/grey Fasten at side of the relay carrier X856 F Blue relay on base blue yellow/black red/green xred Plug into relay carrier X43 G Green relay on base white/blue brown/black xred Fasten at side of the relay carrier X09 H Open contact green/white Connect with quick connector at main wiring harness with cable colour GN/WS X6830 I Open contact grey/red Connect with quick connector at joint connector box with cable colour GR/RT X806 J Connector with twin-lead terminal white/blue Plug unpinned cable pin 3, light check module, cable colour WS/BL, in socket housing. Plug cable with cable colour WS/BL in light check module, pin 3. X343S K Ring terminal red At power distribution box, left side of vehicle, spare wheel recess X345 L Ring terminal brown At earth pin at joint connector X00 Retrofit/Installation Kit no. 8 44 0 007 47 Date: 03.00 Installation Instructions no. 0 9 0 38 98 EN/6
4. Installation diagram 4 5 6 3 7 F 53 04 EVA Key Roof headlights Switch of roof headlights in roof console 3 Earth pin at joint connector 4 Green relay 5 Black relay 6 Blue relay 7 Power distribution box Retrofit/Installation Kit no. 8 44 0 007 47 Date: 03.00 Installation Instructions no. 0 9 0 38 98 EN/7
5. Install supplementary wiring harness Undo the Torx screws () over the whole roof railing (3 Torx screws on each side) () and lift the roof railing () off. F 53 043 EVA 4 Ø0 mm 3 80mm! Care should be taken to see that the roof outer skin panel () and the two reinforcement plates lying underneath ( and 3) are drilled through. All drill holes should be carefully deburred and treated with BMW customary corrosionprotection measures. 30mm F 53 055 EVA In accordance with the given measurements, mark the centre of the drill hole for cable feedthrough (4) with a marker pen. Lightly centrepunch the centre of the drill hole for cable feedthrough (4). Make the drill hole for cable feedthrough (4) with a drill Ø 0 mm. M4 M3 Make the aperture () for the switch of the roof headlights (d) in accordance with the diagram specifications and the following measurements on the roof console (). M: 3 mm M: 60 mm M3: 43.5 mm M4:.5 mm M M q F 53 068 EVA Stick the frame for the switch of the roof headlights (e) in the aperture () with cyanoacrylate adhesive (for verification refer to BMW parts service, part no. 8 9 407 43). Clip the switch of the roof headlights (d) into the frame for the switch of the roof headlights (e). For US market only For vehicles which are deployed in the US market, the additional warning sticker (q) must be fixed on in accordance with the illustration F 53 068 EVA.This prohibits the use of the auxiliary headlights on the public highway. Retrofit/Installation Kit no. 8 44 0 007 47 Date: 03.00 Installation Instructions no. 0 9 0 38 98 EN/8
5. Install supplementary wiring harness The supplementary wiring harness (a) is installed under the fuse carrier. Remove the joint connector box () from the relay carrier (). Dismantle the relay carrier (). F 53 046 EVA Insert branch cable F X43, blue relay with base, from the rear into a free relay plug-in place in the relay carrier (). F F 53 048 EVA I At joint connector box X806 (), select the cable with cable colour grey/red and fasten to it branch cable I, cable colour grey/red, with the aid of a quick connector (). F 53 049 EVA H Out of the main wiring harness X6830 (), select a cable of cable colour green/white (terminal 5) of mm or 0.75 mm and fasten branch cable H, cable colour green/white, to the cable of cable colour green/white (terminal 5) of the main wiring harness X6830 () with the aid of a quick connector (). F 53 050 EVA Retrofit/Installation Kit no. 8 44 0 007 47 Date: 03.00 Installation Instructions no. 0 9 0 38 98 EN/9
5. Install supplementary wiring harness 5 J 4 3 F 53 05 EVA Pull off the upper black connector X () of the light check module and select the cable of cable colour white/blue (pin 3). Unpin this cable with the aid of an unpinning tool. Plug in the cable, cable colour white/blue, coming from branch cable J, into connector X () of the light check module (pin 3). Plug the -pole socket housing (3) on to the contact socket of the white/blue cable (4) and connect with the pin housing X343S (5) of branch cable J. Fasten branch cable G X09, green relay, and branch cable E X856, black relay, with cable ties at a suitable place behind the joint connector box (). + G E F 53 05 EVA L F 53 070 EVA Make sure there is good earth contact, poor earth contact will impair function! Install branch cables K, cable colour red, and L, cable colour brown, each of cable cross-section.5 mm, along the right sill strip as far as the rear of the rear seat bench. Install branch cable L, cable colour brown, along the series wiring harness () to the earth pin X00 () and connect it.tie back branch cable L and fasten with cable ties. 3 Install branch cable K, cable colour red, along the main wiring harness to the power distribution box X345 () on the left-hand side of the vehicle in the spare wheel recess. Connect the ring terminal () coming from branch cable K to the power distribution box B+ X345 ().Tie back branch cable K and fasten with cable ties to the main wiring harness. Fasten the fuse holder (3) with cable ties to the main wiring harness. K F 53 044 EVA Retrofit/Installation Kit no. 8 44 0 007 47 Date: 03.00 Installation Instructions no. 0 9 0 38 98 EN/0
5. Install supplementary wiring harness! When working in the area of the A-pillar and on the roof side-frame, care should be taken to see that the airbag is not damaged and prevented from functioning properly. B+D C 3 F 53 054 EVA With the exception of branch cables B, cable colour red and brown, C and D, cable colour red and brown, install all remaining cables under the carpet. In the A-pillar, keep free the fastening hole of the A-pillar trim panel (). With the aid of a thin wire, pull through individually branch cables B, cable colour red and brown, C and D, cable colour red and brown, from the fuse carrier between the instrument panel () and A-pillar (3) upwards. Install branch cables B, cable colour red and brown, C and D, cable colour red and brown, along the A-pillar (3) at the series wiring harness and fasten them to the series mounting or with cable ties to the series wiring harness. B D B+D C F 53 056 EVA Install branch cables B and D, in each case cable colour red and brown, as well as C from the A-pillar along the series wiring harness of the roof console () under the roof liner. Fasten branch cables B and D, in each case cable colour red and brown, as well as C with a cable tie to the series wiring harness of the roof console (). Lead the branch cable C to the roof console and install through the roof liner aperture of the roof console. Install branch cable D, cable colour red and brown, to the left-hand side of the vehicle as far as the roof side frame. Install branch cables C and D, cable colour red and brown, as far as possible in the roof liner depression (). B Install branch cable B, cable colour red and brown, for the right roof headlight behind the roof liner contour (). In vehicles with sunroof, loosely fasten branch cable B with a cable tie to the sunroof drainage () (only applies to the right-hand side of the vehicle). Remove the rubber bung (3) from the roof sideframe. 3 F 53 057 EVA Retrofit/Installation Kit no. 8 44 0 007 47 Date: 03.00 Installation Instructions no. 0 9 0 38 98 EN/
5. Install supplementary wiring harness 5 4 3 B B F 53 058 EVA! When working in the area of the roof sideframe, care should be taken to see that the airbag is not damaged and prevented from functioning properly. Remove the airbag from the airbag brackets and replace it after installation of branch cable B.Take care to see that the airbag is properly seated. Do not damage the cable when drawing it through the drill holes (, 4, 5 and ). Guide a thin wire from the roof outer skin panel through the drill holes (, 4, 5 and ) to the roof side frame in the vehicle interior. With the aid of the thin wire, thread branch cable B through the drill holes (, 5, 4 and ) to the outside. Seal drill hole () with Sikaflex 55 FC. Apply the seal (3) in such a way that it makes a good fit in the through hole of the seal moulding with through hole (h). Fix branch cable B in the seal (3) in such a way that branch cable B passes through the drill holes (, 4, 5 and ) without chafing (see magnification). Retrofit/Installation Kit no. 8 44 0 007 47 Date: 03.00 Installation Instructions no. 0 9 0 38 98 EN/
6. Mount roof headlights 4 3 Undo the Torx screw (), connecting the front railing-foot () with the central railing part (3), take it out and keep it. Draw the front railing foot () out of the central railing part (3). Remove the seal (4) from the front railing foot () and keep it safe. F 53 059 EVA f 4 3 Push the seal () on to the front railing-foot of the roof headlight, left (f). Slide the front railing-foot of the roof headlight, left, (f) into the central railing part () and bring the drill holes (3 and 4) into alignment. Dampen the Torx screw (5) with Loctite adhesive 70 and screw together the front railing-foot of the roof headlight, left, (f) and the central railing part (4) with a torque spanner to 9. Nm. 5 F 53 060 EVA 3 4 B h F 53 06 EVA Place the seal moulding, with its through-hole on the left (h) and whose covering tab points to the inner side of the roof, over the roof-railing adapter () and at the same time thread branch cable B through the additional hole in the seal moulding (h).the sealing () at the drilled hole for the cable feed-through should not impair the correct seating of the seal moulding with the through-hole (h). It may be necessary to adapt the sealing (). Place the roof railing (3) on the adapter of the roof railing () and at the same time thread branch cable B from below through the roof railing (3) and through the drill hole in the base (4). Straighten up the roof railing (). Make sure when doing so that all seal mouldings are correctly positioned. Lightly screw the roof railing () to all three roof-railing adapters with the Torx screws (). Press the roof railing () in the centre in such a way that the railing foot lies gap-free on the seal moulding. At the same time screw in the Torx screw () with a torque spanner to.3 Nm. Screw down the roof-railing adapters of front and rear in the same way with a torque spanner to.3 Nm. F 53 06 EVA Retrofit/Installation Kit no. 8 44 0 007 47 Date: 03.00 Installation Instructions no. 0 9 0 38 98 EN/3
6. Mount roof headlights Insert the stabilising ring () in the housing (n). n F 53 063 EVA 4 3 j j n j B F 53 064 EVA Thread branch cable B through the housing base (). Place two half-liners (j) against the housing base () as shown in the magnification. Insert the housing (n) with the half-liners (j) in the base support () in such a way that the halfliners (j) abut the crosspiece (3) and cannot twist round. Straighten up the housing optically and tighten the clamping screws (4) with a torque spanner to 6 Nm. B p Pull the cable ends () of branch cable B through the rubber grommet (p) and fit the rubber grommet (p) in the opening of the housing base (). Shorten the cable ends () to length for fitting the headlight insert and crimp on to each of the cable ends () a blade receptacle (c). c F 53 066 EVA Retrofit/Installation Kit no. 8 44 0 007 47 Date: 03.00 Installation Instructions no. 0 9 0 38 98 EN/4
6. Mount roof headlights n 4 5 3 TOP m F 53 065 EVA The "TOP" marking () should always point to the top. Connect the cable (), cable colour red, to the bulb connector (3) and insulate it. Connect the cable (4), cable colour brown, on to the retaining spring (5). Insert the headlight insert (m) in the housing (n) and make it audibly engage with the housing (n). Install the roof liner completely. Attach branch cable C to the switch of the roof headlights X879 in the roof console. Install the roof console in the roof liner. Retrofit/Installation Kit no. 8 44 0 007 47 Date: 03.00 Installation Instructions no. 0 9 0 38 98 EN/5
7. Function test of roof headlights and adjustment of roof headlights Reassemble disassembled parts in the reverse order. After turning on the ignition, the roof headlight system can be made operational by operating the roof-headlight switch in the roof console (green indicator light).the roof headlights will only illuminate when the high beam light on the vehicle is switched on or the headlight flasher is activated.the roof headlights can be switched off at any time by using the switch in the roof console. After switching off the ignition and then switching it on again, the roof headlights must be made operational again by activating the roof-headlights switch in the roof console. B A F 53 040 EVA To adjust the roof headlights, the vehicle should be positioned at distance A in front of a wall. Switch on the roof headlights. Loosen the clamping screws for mounting the roof headlights and adjust the midpoint of light of the two roof headlights to height B. Make the side adjustment parallel to the low-beam light.tighten the clamping screws for mounting the roof headlights in the base with a torque spanner to 6 Nm. A: 3 m B:.68 m Place the covering caps on the roof headlights. Adjustment of the roof headlights should take place on an even horizontal surface with an unladen vehicle (if possible in the dark). Hand over to the customer the instruction manual (l), the Allen key (k) and the special tool (opening spatula) (r). Retrofit/Installation Kit no. 8 44 0 007 47 Date: 03.00 Installation Instructions no. 0 9 0 38 98 EN/6
8. Paint specifications Paint specifications for PC components The following specifications should be observed if the housing(s) need to be painted. Cleaning Careful cleaning is an absolute requirement. Clean the PC components with a mild thinner (alcohol, plastics universal cleanser). Strong thinners will cause material damage. Use only fresh thinner. Do not use thinner which has been used several times or recycled. Do not abrade painted parts under any circumstances as this will considerably increase the aggressivity of the solvent contained in the thinner and thus promote deterioration. Plastics universal cleanser: e.g. Glasurit Universal Cleanser 54-30 Drying When cleaning has been successfully carried out, dry the parts and let the solvent evaporate. Primer When the parts have dried, a suitable plastics primer should be applied. Plastics primer: e.g. Glasurit K-Plastics Primer 934-0 Glasurit K Plastics Primer 934-00 with Glasurit supplement for Plastics Primer 934-00. Painting The topcoat with a -part topcoat or a -coat application of metallic paint is carried out after the specified drying period of the primer in accordance with the specific method of treatment of the topcoat system used. Suitable systems are e.g. the appropriate primer and paint by the firms Glasurit, Akzo Nobel, PPG. Non-metallic paint: e.g. Glasurit High Solid K topcoat Metallic paint: e.g. Glasurit two-coat topcoat Metallic / Uni 55 Retrofit/Installation Kit no. 8 44 0 007 47 Date: 03.00 Installation Instructions no. 0 9 0 38 98 EN/7
3E X00 6 4 8 30 85 86 87 S069 LCM Signal KL_3 KL_5 X806 58G K43 Lastkreis X650.5 BR.5 BR.5 BR.5 RT.5 RT.5 BR WSBL A5.5 RT.5 RT BRSW A3 3 X WSBL GRRT GESW GEGR BRSW BRSW S_NSL NSL_OUT X6830 KL_5 GN 0.75 GNWS 5 9 8 A7.5 RT.0 BRSW 4 A605 5 A F X4007 9 4 6 X650.5 RTBL X09 X343S X879 X879 GESW X596 X596 X07 BRSW X43 X596 X856.5 BR X345 KL_30 F 53 067 EVA 5 9. Circuit diagram of supplementary wiring harness Retrofit/Installation Kit no. 8 44 0 007 47 Date: 03.00 Installation Instructions no. 0 9 0 38 98 EN/8
9. Circuit diagram of supplementary wiring harness Key X650 X879 X856 X43 X09 X6803 X806 X343S X345 X00 X X4007 Roof headlights left and right 6-pole socket housing Black relay (NLS module) Blue relay Green relay Open contact - connect using quick connector to main wiring harness with cable colour GN/WS Open contact- connect using quick connector to main wiring harness with cable colour GR/RT Connector with twin-lead terminal Ring terminal - connection to power distribution box Ring terminal - connection to earth pin at joint connector Light check module Fuse holder Retrofit/Installation Kit no. 8 44 0 007 47 Date: 03.00 Installation Instructions no. 0 9 0 38 98 EN/9