o Teile und ZubehGr - Einbauanleitung F 9901968 Einbausatz Xenon-Licht mit automatischer Leuchtweitenregulierung BMW Ser-Reihe (E39) LHD BMW Ser-Reihe (E39/2) LHD Installation kit - xenon headlights with automatic headlight range adjustment BMW 5 Series (E39) LHD BMWS5 Series (E39/2) LHD1. Important Information Intended for use in BMW dealership network only. Specialist knowledge as well as knowledge of the vehicle electrical system required. These installation instructions apply only to left-hand drive (LHD) vehicles. Installation time required 2.0 hours The installation time may vary depending on the condition and equipment of the vehicle. FN vrs station xt nay ony 00 insted in connection witha noasgne washer system *Option SA 500 headlight washer system must be retrofitted first if the vehicle was not equipped with this optional extra in series production or if $A 500 headlight washer system has not been retrofitted, as the installation kit xanon headlight with automatic headlight range adjustment must only be installed in conjunction with SA 500 headlight washer system. +i installed, the latent heat accumulator must also be removed from the vehicle, The latent heat accumulator must be removed and installed in accordance with the instructions provided in the currently applicable Repair Instructions. Make sure that the warning sticker provided in the installation kit is affixed to the cross member above the headlight This xenon headlight installation kit does not require encoding, Instructions for checking the level sensor and the cold light scan module are provided in Section 2.4 and in the information leaflet (Section 4). If changes are made to the running gear or repairs conducted on the rear axle, the adjustment procedure for the level sensor must be carried out as described in Section 2.4 and in the information leatlet (Section 4) +Place the information leaflet (Section 4) and the white 2-pin socket housing (wire jumper, red wire) unplugged during the adjustment procedure in the car's glovebox so that readjustment can be carried out itmacessary. < Safety notes Particular care must be taken when installing cables/lines to ensure they are not kinked, bent or damaged. Additionally installed cables/lines must be secured with cable straps, (On no account use *Seotchiock quick-action connectors" as they can cause interference and disturbances in the vehicle electrical system. If specified pins or slots are already used, corresponding jumpers, double arimp or parallel connections are to be used. To avoid problems, make sure you follow the specified cable routes in the vehicle precisely.241 Connections overview of xenon headlight wiring harness Notes Refer to general information as well as safety notes in Section 1 ‘Open out fold-out page! (Page 2-19) tem Description Cable colour Connection location in vehicle A | Xenon headlight wiring harness - - At | Black 8-pin socket housing - {Rt lovel sensor in rear right wheelhouse A2_| White 2-pin pin housing White Connected to branch A, white 2-pin socket housing, Brown with fed wire jumper from xenon headlight wring hamness A(after adjustment connected to white 2-pin socket housing 3 (dummy, green wie) ) 3 | White 2-pin socket housing Red Connected to branch A2, white 2-pin pin housing from {wie jumper) xenon headlight wiring harness A (unplugged as part of adjustment procedure and replaces by white 2-pin socket housing 8 (dummy. green wire} (see Section 2.4) ) Ad | Black t-pin pin housing Yellow/blue | At black t-pin socket housing 1 provided, with released, | terminal 56 BR plugged-in socket contact PIN 8 from white 15-pin light | edule connector X88 | 1 | Black, t-pin socket housing With raloased, plugged-in sockst cantact PIN 3 from white 15-pin light module connector X38 at branch Ad of xenon headlight wiring harness A ‘AS | t-pin socket contact, Yellow/blue | In released plug-in siot PIN 3 of white 15-pin light terminal 56 BR edule connector X38 86 | Connection cable, terminal LWAP Yellowired | With insulation displacement connector at wiring loom of black 54-pin ight module connector X1011% yellow/red ‘wire, PIN 34 AT | Gable eye dia. 6 mm Brown At ground terminal point X10012 infront area of right terminal 31 ground hand entrance 2 | Free t-pin socket contact On vehicles equipped with SA 500 headlight washer system in series production (On vehicles with retrofitted SA 500 headlight washer system Free 1-pin socket contacts are crimped onto free wire ends of disconnected headlight washer system pump connector X4011 AB | Black 2-pin socket housing - On vehicles equipped with SA 500 headlight washer system in series production Branch A8 is not required. ‘On vehicles with retrofitted SA 600 headiight washer system With crimped and connected socket contacts 2, PIN 1, bbrown wire and PIN 2, biack/brown wire from headlight, washer system pump connector X1011, at branch A8 of xenon headlight wiring harness Atem Description Cable colour Connection location in vehicle Ag Black 2-pin pin housing Brown Black/brown On vehicles equipped with SA 500 headlight washer system in series production Branch A9 is not required {tie back) ‘Gn Vehicies with retrofitted SA 500 headlight washer system Al branch A8 black 2-pin socket housing with crimped and connected socket contacts 2, PIN 1, orown wire and PIN 2, black/brown wire irom headlight washer system pump connector X1011 ato Black 2-pin socket housing Brown Black/orown On vehicles equipped with SA 500 headlight washer system in series production Branch A10 not required (insulate and tie back) On vehicles with retrofitted SA 500 headlight washer system ‘At washer fluid pump for headlight washer system in front right wheelhouse White 2-pin socket housing (ummy) Green After carrying out adjustment, at brane A2 from xenon, headlight wiring harness A (remains connected to branch ‘A2 of xenon headlight wiring hamess A)2.2 Installation of xenon headlight Notes Refer to general information as well as safely notes in Section 4 Open out fold-out page! (Page 2-23) line description of the installation procedure refers to the left-hand side of the vehicle. The same procedure is to be carried out analogously when installing on the right-hand side of the vehiicie, « Fig. A to Fig. D shows the removal of the halogen headlights. Fig. E to Fig. G shows the mounting of the cold light sean module on the xenon headlights Fig. H to Fig. I shows the installation of the xenon headlights Continue with Section 2.3F 39.0201 B F29.02038 F 39 0202 BF 29 0205 B F 39.0204 82.3 Installation of level sensor Notes Refer to general information as well as safety notes in Section 1 Preparation Remove rear right wheel Open out fold-out page! (Page 2-27) Continue with Section 2.42.4 Installation of xenon headlight wiring harness Notes Refer to general information as well as safety notes in Section 1 Preparation Print out fault code memory Disconnect battery Remove front right wheel Expose wipe/Awash reservoir on right-hand A-pillar behind the wheelhouse cover and remove wipe/wash reservoir Expose light module at right-hand A-pillar in vehicle interior Expose ground terminal point in front area of right-hand entrance Open out fold-out page! (Page 2-51) Fig. A The figure shows the front passenger's footwell. Fold back carpet (1) in front passenger's footwell on left next to Acpillar and remove cover (2) Fig. B Only for vehicles up to production date 9/98 equipped with SA 500 headlight washer system in series production. Mark hole (1) at distance A and in centre with respect to existing rubber grommet (2), centre punch and drill a 30 mm dia, hole (1) using a step dril. Debur hole, carefully remove drill swarf and treat blank points with BMW approved corrosion protection measures, Az 25mm FN rake paricuiar car whe ding to ensure that the cables and hos0s inthe font right whestnouse are not damaged. « Fig. C Only for vehicles from production date 9/98 equipped with SA 500 headlight washer system in series production. Mark hole (1) in centre of recess (2), centre punch and drill a 30 mm dia. hole (1) using a step drill. Debur hole, carefully remove drill swarf and treat blank points with BMW approved corrosion protection measures. PN sao partir car wnt ating to eneure tat the cables and noses inthe font rant wheehouse are nat damaged. Fig. D Only on vehicles with retrofitted SA 500 headlight washer system. Press grommet (1) into vehicle interior and then push back connector (2) for washer fluid pump of headlight washer system through opening into vehicle interior,Fig. E Route xenon headlight wiring harness A from level sensor (1) along the brake line on the right-hand side of the vehicle to the front right wheelhouse and secure with cable straps. Route branches A2 to A9 through the 30 mm dia. hole (3) in the wheelhouse into vehicle interior. Fit rubber grommet (2) on xenon headlight wiring harness A in the 30 mm dia. hole (3) and install the wioe/wash reservoir. ‘Connect branch 10, black 2-pin socket housing of xenon headlight wiring harness A, to washer fluid pump for headlight washer system. FR on vetices equipped in series production with $A 500 headlight washer system insulate and tie back branch A10, black 2-pin socket housing of xenon headlight wiring harness A (not required). < Fig. F Using side cutter (2) cut off displaced connector 1 shown in Fig. D for washer fluid aump of headlight washer system. Strip insulation from the two free wire ends (4) and crimp on t-pin socket contacts (2) provided. Now plug socket contacts (2) into provided black 2-pin socket housing, plug in branch A8 and lock socket housing, Brown wire in PIN 1 Black/brown wire in PIN 2 Connect branch A8, black 2-pin socket housing with connected socket contacts (2) to branch AQ, black 2-pin pin housing of xenon headlight wiring harness A. Fig. Unplug white 15-pin connector X38 from light module (2), open and release. Unplug existing 1-pin socket contact (3) from plug-in slot PIN 3, yellow/blue wire, of white 15-pin light module connector X88. Connect unplugged 1-pin socket contact (3), yellow/blue wire, to supplied black 1-pin socket housing (1). Plug branch AS, 1-pin socket contact, yellow/blue wire, of xenon headlight wiring hamess A into white 15-pin connector X38 at plug-in slot PINS. Lock white 15-pin connector X38, close and connect to the light mociule. Connect black +-pin socket housing (1) with connected *-pin socket contact (3), yellow/blue wire, from white 18-pin connector X88 to branch Ad, black +-pin pin housing, yellow/olue wire of xenon headlight wiring harness A. Fig. H Unplug and open black 54-pin connector X10117 of light module (1). Connect branch A6, free wire end, yellow/red wire, of xenon headlight wiring harness A with double insulation displacement connector (2) to yellow/red wire, plug-in siot PIN 84, of black 54-pin connector X10117 (if necassary, open up the wiring loom of black 54-pin connector X10117 a litle to facilitate the insulation displacement connection). Close black 84-pin connector X10117 and connect to the light module. Pine free wire end of branch A6 must not protrude from the insulation displacement connection. € Fig. | Firmly secure branch A7, 6 mm diameter cable eye, brown wire of xenon headlight wiring harness A at ground terminal point X10012 in front area of right-hand entrance. Fig. J Remove instrument cluster cover (1). Unclip the control unit for manual headlight range adjustment (2), disconnect and replace by the supplied cover (3). Insulate unplugged wiring loom and tie back. Reinstall instrument cluster cover (1). Adjustment Reassemble vehicle in reverse order of removal and connect battery as it must be moved for the adjustment procedure. Eline footwell on the right-hand side of the vehicle, however, must remain open for the adjustment. 4 Now move vehicle and carry out the adjustment procedure described under Fig. K.Fig. K The vehicle should be parked unladen on a flat and even surface for the purpose of automatic adjustment of the level sensor. Disengage gear or selector lever in position "N*. Release handbrake and start vehicle. Make sure that, ‘the battery voltage is not below 13.0V for the adjustment of the level sensor (battery must be charged). Unplug branch A3, white 2-pin socket housing (wire jumper, red wire) from branch A, white 2-pin pin housing of xenon headlight wiring hamess A. The adjustment is now completed. Now connect white 2-pin socket housing (8) (Dummy, green wire) to the now free branch A2, white 2-pin pin housing of xenon headlight wiring harness A. Electrical adjustment is now functional. Park vehicle and switch off ignition. Install ight module and tie back branches A2 to A9 of xenon headlight wiring harness A with cable straps, PN eraco ciscornected branch AB, white 2-pn socket hosing (re umpor red wre] and the information teal (Section 4) in the car's glovebox as the adjustment procedure must be repeated in the event of any changes made to the chassis or repairs carried out on the rear axle. 's information for checking the cold light scan module ifthe message ‘check low beam headlight or the symbol" appears in the instrument cluster display, it is possible that fuse (1) in the cold light scan module (2) is defective (5600 mA slow-blow fuse). After replacing the fuse, there stil may be a fault in the cold light scan module or in the xenon headlight (replace cold light scan module or xenon headlight). formation for checking the level sensor The level sensor in the rear right wheelhouse is checked as follows: - Expose light module (1) in right-hand A-pillar - Park unladen vehicle on flat and even surface: - Disengage gear or selector lever in position *N* and release handbrake. - Connect voltmeter between branch A6, yellow/red wire of xenon headlight wiring harness A and ground, - Start vehicle. - Measure voltage (setpoint 1.0 V). - Luggage compartment laden with 150 kg (2 persons} - The voltage value must increase (approx. 1.2 to 2 Volt) after 20 seconds. - If the voltage does not increase, either the control rod is detached (fixed) or the level sensor is defective. Concluding operations Reassemble footwell on right-hand side of vehicle. Reconnect battery. Carry out function check. Print out fault code memory Adjust headlight with headiight adjuster (the headlights must be set mechanically to H-1%). Encoding ‘This system does not require encoding.F.99 0208 8 F39.02208 F39.0215B F390 02148F390211B F 39 02088 Fs9 021383 Circuit diagram of xenon headlight wiring harness Open out fold-out page! (Page 3-3) xoot* Black 2-pin socket housing, connection washer fluid pump x002" Black 8-pin socket housing, level sensor connection xo03" Black 2-pin pin housing, adapter connection for washer fluid pump xo04" White 2-pin pin housing, coding loop connection x005* Black 1-pin pin housing, light module connection, connector X98, white 15-pin socket housing xo06" Free wire end, light module connection, connector X10117, black 54-pin socket housing, PIN 34 (insulation displacement connection) x38 ‘+-pin socket contact, light module connection, connector X38, white 15-pin socket housing PIN 3 x10012 6 mm dia. cable eye, ground connector X10012 The items marked with * refer only to this circuit diagram. All other items correspond to the BMW Service circuit diagrams.xoor | 4 ! 4 L X02" up oe a aso Lage oy [age ove ors 28° 428 Be 2, Behn a0 [ago on ar dors os ors : ps X003" i. X10012 } ‘xo06*4. Information leaflet (to be kept in vehicle) Adjustment Before carrying out the adjustment, the vehicle must be moved and the light Hf module at the bottom of the right-hand A-pillar exposed, Disconnect white j| [/ | 2:pin socket housing (3) (Oummy, green wire) from branch A2, white 2-pin pin A | housing of xenon headlight wiring harness @ and connect white 2-pin socket | I housing branch 8 (wire jumper, red wire) kept in the glovebox to branch A2, My white 2-pin pin housing of xenon headlight wiring harness A. The vehicle should be parked unladen on a flat and even surface for the purpose of automatic adjustment of the level sensor, Disengage gear or selector lever in position *N* Release handbrake and start vehicle. Make sure that the battery voltage is not below 13.0V for the adjustment of the level sensor (battery must be charged). Disconnect branch A3, while 2-pin socket housing (wire jumper, red wire) from branch A2, white 2-pin pin housing of xenon headlight wiring harness A. The adjustment is now completed. Reconnect white 2-pin socket housing (3) (Dummy, green wire) to free branch A2, white 2-pin pin housing of xenon headlight wiring harness A. Fovomte Electrical adjustment is now functional. Park vehicle and switch off ignition Prisco cisconnocted oranch a9, tite 2-pin socket housing (wire jumper, red wire} and the information leaflet (Section 4) in the car's glovebox as the adjustment procedure must be repeated in the event of any changes made to the running gear or repairs carried out on the rear axle. Reinstall the light module and adjust headlights with headlight adjuster (the headlights must be set mechanically to H-196) Encoding This system does not require encoding. Notes on checking cold light scan module Ifthe message "check low beam headlight or the symbol” appears in the instrument cluster display, it is possible that fuse (1) in the cold light scan module (2) is defective (500 mA slow-blow fuse). After replacing the fuse, there sooma vice 4 still may be a fault in the cold light scan module or in the xenon headlight (replace cold light scan module or xenon heaclight) Notes on checking the level sensor ‘The level sensor in the rear right wheelhouse is checked as follows: ~ Expose light module (1) in right-hand A-pillar ~ Park unladen vehicle on flat and even surface - Disengage gear, release handbrake - Connect voltmeter between branch A, yellow/red wire of xenon headlight j| wiring names A and ground. ~ Start vehicle ~ Measure voltage (setpoint 1.0) - Luggage compartment laden with 150 kg (2 persons) - The voltage value must increase (approx. 1.2 to 2 Volt) after 20 seconds raowaoe | ~ If the voltage does not increase. either the control rod is detached (fixed) or the control sensor is defective,Circuit diagram of xenon headlight wii xo01* xoo2" xo03* xoo4" xo05* xo06* x38 x10012 ing harness Black 2-pin socket housing, connection washer fluid pump Black 8-pin socket housing, level sensor connection Black 2-pin pin housing, adapter connection for washer fluid pump White 2-pin pin housing, coding loop connection Black ‘-pin pin housing, light module connection, connector X88, white 16-pin socket housing Free wire end, light module connection, connector X10117, black 54-pin socket housing, PIN 34 (insulation displacement connection) 1-pin socket contact, light module connection, connector X38, white 15-pin socket housing PIN 3. 6 mm dia. cable eye, ground connector X10012 The items marked with * refer only to this circuit diagram. All other items correspond to the BMW Service circuit diagrams. oor i voir oe ye swore ()) roe TT x05"