BMW - X5 Diesel (E70) - Workshop Manual - 2006 - 2006

Installation Instructions 1 of 23 Equipment Parts, Trailer Hitch Accessory Development Ver 3.0 June 2012 SUBJECT TRAILER HITCH KIT (US Only) - P/N 71 60 2 156 525 MODEL X5 (E70): X5 Diesel (E70): X5 M (E70) Select Vehicle Production 10/06 - On* Select Vehicle Production 10/08 - On* Vehicle Production 07/09 – On * Not for vehicles with BMW Performance Aerodynamic kit. SUGGESTED INSTALLATION TIME: 2.5 HOURS** **Suggested installation time includes re-coding of the vehicle only for this retrofit kit. This time is based on a vehicle that is at the current software level and does not require any updates. Please refer to SI B09 05 01 for latest BMW approved Retrofit coding procedures. Total installation time may vary depending on vehicle options and equipment. The instructions below are developed for BMW vehicles and are not to be compared to any other existing instructions for vehicles other than BMW. No methods other than those specified in this document are to be used for installation in BMW vehicles. Left and right are determined from the driver’s seat. Carefully read all instructions and supplements before proceeding with the installation. Reference should be made to TIS for instructions dealing with a stock part of the vehicle but not stated in detail in these instructions. The instructions were complete and up to date at time of publication; however, changes to the vehicle or installation may have occurred. Please report any problems or changes noted with the installation to BMW Technical Hotline, along with VIN, date of manufacture and as much detail as possible. Note: Pages 22 and 23 (BMW X5 (E70) Trailer Hitch Guidelines and Cautions) of these installation instructions should be given to the vehicle owner (customer) after installation of the trailer hitch kit for approved towing procedures.   DO IT RIGHT THE FIRST TIME, ON TIME, EVERY TIME   Installation Instruction P/N 01 29 0 439 467  2012 BMW of North America, LLC 2 PARTS INFORMATION Contents of Kit - P/N 71 60 2 156 525 Description Cross Member with Receiver Tube Cross Member Mounting Nuts White Capacities Label Receiver Tube Cover/Cap Electrical Kit Contents of Electrical Kit: Trailer Control Module (AHM) Trailer Hitch Wiring Harness 7-pin Trailer Wiring Connector 7-pin to 4-pin Trailer Wiring Adapter Hardware Kit Qty 1 8 1 1 1 BMW Part Number 71 60 0 440 592 71 60 6 772 024 71 60 0 413 357 71 60 0 303 882 71 60 2 156 526 1 1 1 1 1 61 35 9 186 177 61 12 2 155 760 N/A 72 11 0 404 323 N/A ADDITIONAL REQUIRED PARTS Description Rear Bumper Trim Piece Kit (Vehicle 04/10 – On) Rear Bumper Trim Piece Kit (Vehicle 10/06 - 3/10) Rear Bumper Trim Piece Kit X5 M (07/09 – On) Rear Bumper Trim Piece Kit X5 M Sport Package (ZMP) (04/10-on) Ball Mount Kit BMW Part Number 71 60 2 185 557 71 60 0 035 371 71 60 2 185 556 71 60 2 230 141 71 60 0 413 358 ADDITIONAL OPTIONAL PARTS Description Electric Trailer Brake Controller 3 ft Trailer Connector - 4/5 Wire Flat*** 5 ft Trailer Connector – 7 Blade Round (Female) 5 ft Trailer Connector – 7 Blade Round (Male) BMW Part Number 82 11 0 420 082 61 13 0 412 965 61 13 0 412 966 61 13 0 412 967 *** Not for use with trailers with electric brakes. Installation Instruction P/N 01 29 0 439 467 3 LOCATION OF KIT PARTS Illustration S71 06 U02 shows the location of the major components/connections of the X5 (E70) Trailer Hitch System. A = Trailer Hitch Receiver B = Vehicle Body Pass Through Grommets for Trailer Wiring Harness C = Trailer Control Module (AHM) For MY2011 – On Vehicles: For MY2007 – MY2010 Vehicles: For X5 M Vehicles (all production): For X5 M Package Vehicles: Proceed to page 4 for bumper preparation Proceed to page 6 for bumper preparation Proceed to page 7 for bumper preparation Proceed to page 9 for bumper preparation Installation Instruction P/N 01 29 0 439 467 4 Bumper preparation (Vehicle production 04/10 – On) 1. Remove Rear Fascia/Lower Bumper Protector Assembly (1) from vehicle. 2. Separate Lower Bumper Protector from Rear Fascia. 3. Use a reciprocating saw (such as the Blue-Point ® # AT192) to carefully cut away the area along score line to remove section (1) Note: Please reference both steps 5 and 6 for proper positioning of the cutout template from kit 71 60 2 185 557 4. Cutout Paper Template along dotted line. 5. Position template (1) on Rear Fascia with tape, or a light adhesive over area to be removed. Note the profile of the template that should align with the features of the Rear Valance (2) 6. Wrap the template around the Rear Fascia. Note the solid line on the template (2) that should align with the radius (1) of the Rear Valance. 7. Mark the area around the template and, with a reciprocating saw, or similar tool, carefully cut away the area. 8. Clean and smooth cut edge with an X-Acto™ Knife and/or a fine hand file. Installation Instruction P/N 01 29 0 439 467 5 9. Assemble the Rear Fascia (2) and Lower Bumper Protector (1). 10. Trim the Lower Bumper Protector (1) along the cuts made in steps 4-7. (remove Grey section). 11. Clean and smooth cut edge with an X-Acto™ Knife and/or a fine hand file. 12. Snap Trim Piece in to place over the Rear Fascia and Lower Bumper Protector Assembly. Note: Fitment is snug. Slight bending of the rear valance may be required. Ensure that all of the trim piece tabs are engaged. 13. Use the two 1/8” pop-rivets and backing washers from the kit [installed into the 1/8” holes (2)] to secure the lower edges of the trim piece to the Fascia. Proceed to page 11 Installation Instruction P/N 01 29 0 439 467 6 Bumper Preparation (Vehicle production 10/06 – 03/10) 1. Remove bumper fascia from vehicle and position as illustrated. Protect outer surface of fascia during the following operations. 2. Tape around outer edge of scribe line (1) to more clearly mark line to be cut. Note: There may be an additional “outer” line (2) on the left side of the fascia. Ignore this line if present. The correct cut out line (1) is symmetrical and matches the profile of the bumper fascia trim piece P/N 71 60 0 035 371. Caution: Wear safety glasses during the following operations. 3. Use a reciprocating saw (such as the BluePoint ® # AT192) to carefully cut along cut line (1). Note: Depending on the type of tool used and the confidence of the user, you may find it easier to remove the fascia material in two steps. Remove the majority of material (A) first then make the final cut, removing area (B). Making the final cut as smooth and accurate as possible will make the installation of the bumper fascia trim piece (in the next step) easier and result in a more “finished” look. 4. Clean and smooth cut edge with an X-Acto™ Knife and/or a fine hand file. 5. Remove tape from fascia; clean/wipe area around cut line. Turn fascia over to access outer cosmetic surface of fascia. 6. Install bumper fascia trim piece (1) along the cut line, starting at the top corner as illustrated, using both hands to work the tabs around and behind the fascia. 7. Use the two 1/8” pop-rivets and backing washers from the kit [installed into the 1/8” holes (2)] to secure the lower edges of the trim piece to the fascia. Proceed to page 11 Installation Instruction P/N 01 29 0 439 467 7 Bumper preparation for M vehicles only 1. Remove center rib on M bumper (1) to aid in positioning of template. 2. Position template (1) on bumper with tape, or a light adhesive over area to be removed, bottom edge of existing cutout for alignment reference. 3. Mark the area around the template as shown. 4. Use a reciprocating saw (such as the Blue-Point ® # AT192) to carefully cut along marked area. Note: Making the final cut as smooth and accurate as possible will make the installation of the cut out trim strip (in the next step) easier and result in a more “finished” look. 5. Clean and smooth cut edge with an X-Acto™ Knife and/or a fine hand file. Installation Instruction P/N 01 29 0 439 467 8 6. At one end of the cut, install trim strip (1) over exposed edge by pushing firmly onto bumper until the cut edge is seated in the bottom of the trim’s channel. 7. Continue trim strip (1) around circumference of the opening. 8. Trim excess material if needed. Proceed to page 11. Installation Instruction P/N 01 29 0 439 467 9 Bumper preparation for M Sport Package (ZMP) Vehicles 1. Remove the center trim (1) on the bumper (2) to aid in positioning the cutout template. 2. Position the cutout template (2) on bumper (1) with tape, or a light adhesive over area to be removed. Note the alignment marks on the template and ensure that the key template positioning mark (3) is referenced. 3. Use a reciprocating saw (such as the Blue-Point ® # AT192) to carefully cut along cut line. Making the final cut as smooth and accurate as possible will make the installation of the bumper fascia trim piece easier and result in a more “finished” look. 4. Install the previous removed center trim. Reference the previous bumper cut from the backside of the bumper and cut out the center trim to match the bumper cutout (2). Installation Instruction P/N 01 29 0 439 467 10 5. Install the Trim Piece (1) by pressing the tabs around the bumper cutout and center trim. 6. After the Trim Piece (1) is positioned mark the drill hole locations (2) in the Bumper, drill Proceed to page 11 Installation Instruction P/N 01 29 0 439 467 11 Trailer Hitch Installation (All models) 1. Remove and discard steel bumper (1) and eight mounting nuts (2) from vehicle. Note: Access to the upper mounting nuts will be easier if the tailgate (3) is lowered approximately 45°. 2. If vehicle is equipped with optional Comfort Access (SA 322), note position of antenna (1) and mounting/adjustment screw (2). Antenna position may have to be changed when installing trailer hitch wiring harness. Note: If so equipped, antenna wiring harness must be disconnected from Antenna (1) and re-routed back through body access hole, into vehicle fuse panel area. (Reference illustration S71 06 U12, page 10, in wiring section) 3. Install trailer hitch (1) using eight HCN-nuts with spaces (2) from installation kit. Note: Access to the upper mounting nuts will be easier if the tailgate (3) is lowered approximately 45°. Note: Torque nuts to 108Nm (80ft. lbs.) Reference TIS AZD 51 12 for additional torque information as required. 4. Install 7-pin trailer connector (1) onto mounting plate as illustrated using four T25 TORX head screws (2) from installation kit. Installation Instruction P/N 01 29 0 439 467 12 Vehicle Wiring / Routing 1. Remove cover panel and storage well from right side of vehicle cargo area to access main fuse panel and vehicle wiring. 2. Disconnect vehicle battery. 3. Trailer hitch wiring harness will be routed with connectors (1) and (2) located at the 7-pin trailer connector area near the receiver tube and connectors (3) through (10) inside the vehicle at the fuse panel location. Note: Small plastic bag (containing 2 connectors and 4 pins), taped to wiring harness is to be given to customer for future option use. 4. Route trailer wiring harness behind 7-pin connector mounting plate (4), behind receiver tube & supports - with Comfort Access antenna connection at location (5), along vehicle body below trailer hitch, looped behind body panel (2) and through body access hole (1). Note: Reference illustration S71 06 U10 below and next steps if vehicle equipped with optional Comfort Access and or PDC. 5. Secure harness along body utilizing integral body studs and harness oval plastic mounting clips located at (3) and behind body panel near areas (1) and (2). Note: MY2007 – MY2010 vehicles with optional Comfort Access (1) and/or PDC (2) will have one or both body access holes occupied. Vehicles without either option will have a blank plug covering these holes. 6. If the vehicle has Comfort Access the antenna wiring harness must be disconnected from the antenna and (with grommet) re-routed back through body access hole (1) into vehicle fuse panel area. Note: This antenna wire will be connected to the comfort access antenna wire that is part of the trailer wiring harness. For MY2007 – MY2010 please proceed to step 14 For all X5 M and MY2011 – On please proceed with step 7 Installation Instruction P/N 01 29 0 439 467 13 X5 M and MY 2011 - On vehicles equipped with exhaust flap vacuum hose require additional steps 7 - 13 7. Detach hose (1) from inline coupling in bumper area. 8. Remove the inner rubber body grommet (1) and sealing tape from hose. 9. Remove hose from rubber body grommet (1) and re route hose (2) through second body hole for comfort access/PDC wiring shown in step 7 of Vehicle Wiring / Routing instructions. 10. With a suitable wire fishing tool (1) securely tape the tool (2) to the hose (3). Installation Instruction P/N 01 29 0 439 467 14 11. Grasp the wire routing tool (1), and pull the hose (2) through the grommet alongside the existing comfort access/PDC wiring. 12. Reseal the grommet to the hose/wire harness with electrical tape. 13. Re connect hose to the coupling. 14. Connect trailer-wiring connector (2) to trailer connector (1). Note: Ensure that harness connector (2) is fully seated and gray locking tab is in full locked (closed) position. Note: Wrap trailer wiring harness several times with a 2 inch wide piece of duct tape (3) in the area where the harness passes along the edge of the vehicle body panel (4). This will add an additional layer of protection to the harness. 15. If vehicle is equipped with optional Comfort Access connect 2-pin connector [blue/gray, blue/yellow wires (2)], branched from trailer wiring harness (1), to antenna (3). 16. Adjust antenna position as required. (Reference Illustration S71 06 U 07 page 9). 17. Locate the 3-pin vehicle BUS connector (2) and (if vehicle so equipped) re-routed Comfort Access Antenna Wire with connector (1). Note: Illustration does not show trailer wiring harness for clarity. Note: In the following steps, reference page 10 for Wiring Harness Diagram (S71 06 U11) and detailed description of harness connections and wire colors. Installation Instruction P/N 01 29 0 439 467 15 18. Connect 3-pin connector (green, orange/green, black/yellow wires) from trailer wiring harness (5) to vehicle BUS connector (2). 19. If vehicle so equipped, connect 2-pin connector (blue/gray, blue/yellow wires) from trailer wiring harness (5) to connector (1) on re-routed Comfort Access antenna harness. 20. Carefully route single blue/brown wire from trailer wiring harness along existing harnesses to area behind right tail light assembly. Secure all harnesses with wire-ties (3) & (4) from installation kit. 21. Locate and remove Connector X318 (1) from Tail Light Assembly. 22. With connector X318 (1) removed from tail light assembly, use BMW approved tap connector (3) p/n 61 13 8 364 566 [included in kit] to connect blue/brown wire from trailer wiring harness (4) to the blue/brown wire (pin 3) in the connector. Make certain single wire from trailer wiring harness does not protrude from tap connector. 23. Reconnect connector X318 to tail light assembly. 24. Install Trailer Control Module (AHM) (1) into empty slot in module carrier as illustrated. 25. Connect 16-pin connector (2) from trailer wiring harness to AHM module. Installation Instruction P/N 01 29 0 439 467 16 26. Connect trailer wiring harness ground (single brown wire with ring connector) (1) to vehicle ground point as illustrated. Note: 4-pin connector (red, yellow/red, yellow/green, brown wires) branched from trailer wiring harness near ground wire branch is for optional electric trailer brake control and is not used for this installation. 27. Remove three screws from fuse panel (1) and carefully turn panel around to access individual connectors. Reference TIS RA 61 13 042 as required. 28. Plug paired single wires from trailer wiring harness (2) into fuse panel blue connector X11016 as follows: 29. Red/blue wire to pin position1 (Fuse F116). Install 20 amp fuse from installation kit. 30. Red wire to pin position 3 (Fuse F118). Install 30 amp fuse from installation kit 31. Plug paired single wires from trailer wiring harness (3) into fuse panel black connector X11014 as follows: 32. Red/violet wire to pin position 2 (Fuse F143). Install 25 amp fuse from installation kit. 33. Red/green wire to pin position 3 (Fuse F144). Install 25 amp fuse from installation kit. Wiring is Complete Proceed to Assembly and Ball Mount Installation section unless, vehicle is equipped with optional PDC. Re-mount fuse panel. Secure all harnesses with wire-ties as required. Re-connect vehicle battery Installation Instruction P/N 01 29 0 439 467 17 Only for MY07 and select MY08 Vehicles equipped with optional PDC 1. Install wire-ties with brackets (1) from installation kit onto mounting studs (2), located on trailer hitch cross member, as illustrated. 2. PDC wiring (1) is to be re-installed on bumper fascia in original locations with the exception of harness center section which must be attached to the hitch cross member as illustrated. Note: Depending on harness tension, wrap areas of harness that might come into contact with receiver tube vertical supports with duct tape to provide an additional layer of protection to the harness. Proceed to Assembly and Ball Mount Installation section. Installation Instruction P/N 01 29 0 439 467 18 Reassembly and Ball Mount Installation 1. Reinstall bumper fascia and vehicle interior components. Note: Clean bumper with a mild cleaner and or alcohol in the area where label (A) is to be positioned. Important: Install white Capacities Label (A) from installation kit onto bumper fascia centered just above trailer hitch receiver tube as illustrated. 2. Ensure that silver Caution Label (A) is located on ball mount as illustrated. Note: Silver caution label is not available as a separate part. Important: Use only the BMW X5 (E70) ball mount kit, available from BMW centers, with the following specifications: A (Drop) = 2 ¼” (57mm) B (Rise) = 1” (25mm) C (Length) = 8” (203mm) 3. Install trailer ball (5) onto ball mount (1) with lock washer (6) and nut (7). Important: Torque nut to 240 foot lbs. (330Nm). Note: Reference information and warnings on ball mount label. 4. Install ball mount assembly (1) into trailer hitch receiver tube (2) by aligning holes in mount and tube and inserting pin (3) and clip (4) as illustrated. Installation Instruction P/N 01 29 0 439 467 19 5. When towing a trailer with a four-pin wiring harness (3). Use the 4-pin to 7-pin adaptor (2) included in the installation kit to connect the trailer electrical system to vehicle connector (1). Note: The adapter should be kept with vehicle at all times. Installation is Complete. Proceed to Retrofit Coding See pages 20 and 21 for customer guidelines / cautions sheets to be left in vehicle for customer reference. Installation Instruction P/N 01 29 0 439 467 20 RETROFIT CODING Note: Please refer to SI B09 05 01 for latest ISTA/P retrofit procedure before starting vehicle coding. Retrofit Trailer Hitch AHM Module using ISTA/P Ver. 2.46.0 or later. Follow approved ISTA/P Retrofit procedures until Retrofit selection appears then: Procedure 1. Select “Load SW” and answer the question as to whether the control units have been replaced with “No”. 2. If a routine for updating the vehicle software appears, completely work through this routine first. Follow the on-screen instructions. Then repeat points 1 to 4. 3. Select the “Vehicle” menu item in the navigation bar. 4. A submenu will appear. Select “Retrofit, Detachable Trailer Tow Hitch”. 5. Confirm the determined routine and the estimated execution time and follow the on-screen instructions. AHMU will be added to the VO. 6. A final report appears on completion of the routine. Other than undeletable fault code entries, this report should contain no error messages. If errors occurred, follow the instructions in ISTA/P user documentation. 7. Perform Complete Vehicle Encoding 8. Turn off the ignition, wait 15 seconds and switch on the ignition again. 9. Now check whether all systems are functioning correctly. If additional problems persist then perform a vehicle battery reset and then submit a PuMA case. Retrofit Coding Complete Installation Instruction P/N 01 29 0 439 467 21 TRAILER HITCH WIRING HARNESS Reference 1 2 3 4 5 6 7 8 9 10 Description 10 pin connector - Connect to back of 7-pin trailer wiring receptacle 2 pin connector (blue/gray, blue/yellow) - Connect to Comfort Access antenna 3 pin connector (green, orange/green, black/yellow) - Connect to vehicle BUSS Single wire (blue/brown) - Lighting Signal for Trailer Control Module (AHM) 2 pin Receptacle (Blue/Gray, Blue/Yellow) - Connect to vehicle Comfort Access antenna harness. 16 pin connector - Connect to Trailer Control Module (AHM) 4 pin connector (red, yellow/red, yellow/green, brown) - Electric Trailer Brake Control Module Single wire (brown) with ring connector - Ground Single wires - Red/violet wire to fuse No.143 (25A), red/green wire to fuse No. 144 (25A) Single Wires - Red/blue wire to fuse No. 116 (20A), red wire to fuse No. 118 (30A) Installation Instruction P/N 01 29 0 439 467 22 BMW X5 (E70) Trailer Hitch Guidelines and Cautions Page 1 of 2 These Guideline Sheets should be left in the vehicle (for customer reference) after installation of the Trailer Hitch ----------------------------------------------------------------------------------------------------------------------------------------  The BMW X5 Trailer Hitch is rated Class 3 (gross trailer weight 6000 lbs., maximum tongue weight 600 lbs.). Never exceed these specifications. This rating is based on a standard equipped vehicle with driver. Additional passengers and/or cargo will reduce maximum vehicle/trailer ratings.  Do not exceed gross vehicle weight or front/rear axel weights as specified in the vehicles Owners Manual and displayed on the Safety Certification Label located on the drivers door jam.  Do not use weight distribution equipment. Use only the BMW X5 (E70) Ball Mount Kit (p/n 71 60 0 413 358) available from BMW Centers with the following specifications. Reference Illustration S71 06 U24. A (Drop) = 2 ¼” (57mm) B (Rise) = 1” (25mm) C (Length) = 8” (203mm) Install trailer ball (5) onto ball mount (1) with lock washer (6) and nut (7). Important: Torque nut 240 foot lbs. (330Nm). Reference information and warnings on ball mount label. Install ball mount assembly (1) into trailer hitch receiver tube (2) by aligning holes in mount and tube and inserting pin (3) and clip (4) as illustrated. Installation Instruction P/N 01 29 0 439 467 23 BMW X5 (E70) Trailer Hitch Guidelines and Cautions Page 2 of 2 These Guideline Sheets should be left in the vehicle (for customer reference) after installation of the Trailer Hitch ----------------------------------------------------------------------------------------------------------------------------------------  Before attaching, loading, or towing a trailer please read the brochure (included with the installation kit, available from your BMW Center, available on line at the NHTSA Web Site www.nhtsa.gov or available by calling the DOT Auto Safety Hotline at 888327-4236): TOWING A TRAILER – Being Equipped for Safety, NHTSA Publication DOT HS 809 433, April 2002.  Check all connections (mechanical and electrical) before and during the towing of a trailer.  Check the function of all vehicle lights and the lights on the trailer before and during the towing of a trailer.  Do not cut, weld, drill or modify the trailer hitch.  Do not modify any wiring or electrical components. When towing a trailer with a 4-pin wiring harness (3) use the 4-pin to 7-pin adaptor (2) included in the installation kit to connect the trailer electrical system to vehicle connector (1). The adapter should be kept with the vehicle at all times. Installation Instruction P/N 01 29 0 439 467