BMW - E60 - Workshop Manual - 2003 - 2003

Installation Instructions Product-Ident: 45165 doorboards with soundsystem, BMW E60/E61 until Bj. 03.2007, all models Technical Details: Car Features: Model/Year: Setup-Advice: recommended amplifier power: 4-doors, also for models with doorairbag, electrical window controls, with co-passenger airbag E60 (07.2003) To reach the best performance, the setup of the radio (Bass, Loudness etc.) should be null or neutral. from 2x 100 - 200 Watt / 2 Ohm Parts list: 1x 1x 2x 2x 4x 1x 1x Doorboards (right+left) BMW 5series E60 sedan/E61 touring - models to 3/2007, covered grills (right+left) BMW 5series E60 sedan/e61 touring -models to 03/2007-, cover: acoustic fabric XE 26 - Neodymium-Tweeter ø 26mm (1") incl. mounting device, Hex nut M4, washer ø 12mm XM 110 - High-End-midrange driver, ø 100mm (4"), incl. adapterring XM 165 - Low midrange driver, power woofer ø 165mm (6,5") 3-way frequency crossover (right+left) BMW 5 E60/E61 sedan/touring - part-no. 45165 Hardware bag, BMW E 60/61 sedan/touring - part no. 45165/41165 10x flat head srew M4 x 30 2x flat head srew M4 x 40 12x hex nut M4 4x PE ring 5,6 x 15 black 2x Velcro strip à 2,5 cm (reserve) 16x washer 20mm Garantee: We grant a manufacturers guarantee of 2 years starting from the date of purchase of the doorboard or sound system from the dealer. Within this guarantee period to our choice we either repair or replace free of charge all defects due to material or workmanship. Exempt from this guarantee are damages due to improper use, wear and tear or damages which have to be led back on wear or interventions by third parties. The guarantee does not cover subsequent damages or such defects that only insignificantly impair the value or the usability of the doorboard/sound system. The guarantee does not cover damages due to external influences. Doorboards with additional or wrong assembly drill holes cannot be returned. These are damages to the doorboard which cannot be repaired again. Installation Instructions Product-Ident: 45165 1 Disassembly of the door card 1.1 Roll down window completely. 1.2 Unclip the airbag cap (A) and unscrew torx screw underneath. 1.3 Loosen all door clips. Unclip the door card on the molding under the window. 1.4 Remove the Torx screw (B). 1.5 Move the door card upward away. Observe the fastening point C. (The clip remains hanging in the door) Backside of the door card 1.6 Remove the Bowden pull wire of the door latch lever. 1.7 Unplug switch for electric window control. 1.8 Disconnect the original loudspeaker plugs and dismount the original speaker. Installation Instructions Product-Ident: 45165 2 Handling of door card: Doorboard alignment 2.1 Before aligning the doorboard the tray on the door card has to be removed. Drill the plastic rivets from the backside and dismount the tray. 2.2 Place the door card on a plane surface. 2.3 Dismount the loudspeakers attached to the doorboard for transport protection --> retain the screws for later assembly. 2.4 Place the doorboard without speakers on the door card and align it: Only precise alignment of the doorboards with the door card warrants optimal fit! Reference points for alignment: - the doorboard fits exactly in the cut-out of the tray. - the lower edge of the doorboard aligns directly to the design line of the door card. - the lower edge of the doorboard is parallel to the lower edge of the door card. 3 Handling of door card 3.1 Use the doorboard as template in order to mark fastening points and cut-outs: Precisely align the doorboard of the door card. Installation Instructions Product-Ident: 45165 4 Marking fastening points 4.1 Marking of the fastening points: Use a thin awl to set the marks on the door card. Example 5 Handling of door card cut-outs The cut out behind the speakers are providing the required full volume of the car door: 5.1 Mark the cut outs for the woofers on the door card. Enlarge them approx. 1cm (= approx. outer diameter of the woofers) IMPORTANT! Check all cut-outs marked: Example The fastenings of the doorboard must have to be screwed with the door card. The fastenings of the door card must not be removed! 5.2 Remove the doorboard again and cut out the positions marked on the door card. Use a compass saw. 5.3 Drill the bore holes for the screws according to the marks set before - use a 4mm drill and enlarge to 7-8mm Example Example Installation Instructions Product-Ident: 45165 6 Fastening doorboard 6.1 Screw in the M4-screws supplied with. Affix the doorboard to the door card. Screw all M4-screws only hand-tight . Secure all screws with washers and nuts. TIP: Treat the screw thread with a liquid for screw-in type fuse. (Speaker vibrations may loosen the screws after some time). Example 6.2 Check again for precise fit and tighten the screws. All cutting edges of the doorboard must fit to the door lining snugly all around without gap! 7 Midrange installation: Original mount of the door card The original speaker in the door card is replaced with the JEHNERT - 100mm High-end-midrange driver: 7.1 Unplug the original speakers. The original speaker fastenings may be used for the installation of the midrange adapter plate (original cables are not needed any more) 7.2 Connect the JEHNERT midrange with speaker cable (1,5 - 4 qmm). Lead the speaker cable to the mount of the crossover in the doorboard. 7.3 Insert the midrange with adapter in the original place(under the sheet metal) and use the original screwing. Secure with the plastic washers ABC supplied with. 7.4 D+E are already pre-installed. Installation Instructions Product-Ident: 45165 8 Tweeter installation - original mount of the mirror triangle with mounting device 8.1 Dismount the mirror triangle and original tweeter. Unplug the cable connection. (Original connecting cables and tweeter will not be used any more) 8.2 Remove the tweeter out of the catch: ---> bayonet catch: turn to the right and pull out of the holding device - by means of the screw. 8.3 Adapt the original tweeter mount on the backside of the mirror triangle to the JEHNERT tweeter. Insert the tweeter and affix with hot melt adhesive i.e. 8.4 Adapt the JEHNERT-tweeter cable with the speaker cable (1,5-4 qmm), length of cable up to where the crossover is installed in the door. In order to avoid vibration noise insulate all cables with insulatingl tape e.g. 8.5 Reinstall the mirror triangle. 9 Adaptation amplifier - crossover circuit / Insulation of the car doors 9.1 Carefully remove the moisture protection foil. 9.2 Insulation of the car doors - Important tips against vibration-noise (see attached installation recommendation) 9.3 Adaptation amplifier - crossover circuit: Lead 1x speaker cable (1,5 - 4 qmm) from amplifier to the crossover circuit: mount of crossover circuit: car door In order to avoid vibration noise secure all cables with insulating tape e.g. 9.4 Reinstall the moisture protection foil to fit precisely. 9.5 For the bass performance the speakers are using the volume of the car door: Place the door card on the car door as template and mark the position for the woofers on the moisture protection foil. Take away the the door card and cut out (u-form see fig.) behind the woofers. Stabilize the lateral cutting edges in order to avoid vibration noise (e.g. use a adhessing tape) 10 Insulation of the door card In order to avoid vibration noise insulate all cables with insulation tape e.g. 10.1 Insulate the backside of the door card e.g. with self-adhesive vibration suppressing insulation fleece – see attached installation recommendation. ATTENTION / danger ! No insulation behind the side-airbags! IMPORTANT: No insulation material behind loudspeaker, door latch lever and fastening points of the door card! Example Installation Instructions Product-Ident: 45165 11 Installation of crossover circuit 11.1 Place the door card on a flat surface, backside up. 11.2 Precable crossovers - see wiring diagram. 11.3 Position the crossover acc. to figure in front of the doorboard and affix with silicone i.e. 12 Installation of the door card onto the car doors 12.1 Check up length of the screws and bolts: In order to prevent damages of mechanic parts of the car doors, please check once again the length of all bolts and screws on the back side of the door card! No touch with any mechanic parts of the car doors! (please shorten if necessary) 12.2 Pull the clip of fastening point C off the car door and insert it in the door card. Backside of the door card clip C 12.3 Clip in the door card on fastening point C (from the front side). 12.4 Fit the door card in contrary order of succession. Final inspection after installation of the door card: Please check all functions of the operating elements such as seat adjustment, opening of the glove box, window winder etc. Installation Instructions Product-Ident: 45165 13 Speaker connection 13.1 Connect all speakers to the crossover circuit according to the wiring diagram (see 11.2). 13.2 Insert woofer. 13.3 Notice: You should check the polarity of all woofers after having connected them to the crossover circuit with a 9 volt battery (input cable on the side of the amplifier): pole of the crossover circuit input + to + of a 9 Volt battery pole of the crossover circuit input - to - of a 9 Volt battery All woofers must move uniformly! Wrong polarity of a woofer can totally equalize the bass sound! 14 Installation of the doorboard grills 14.1 Carefully press grill with Velcro fasteners onto the doorboards: IMPORTANT: The Velcro fasteners stick very strongly! Therefore only press the grills to the doorboard at the end of the installation of the doorboard and the soundsystem! 14.2 Further tips see attached installation recommendation. Insulation of the door lining ! ☞ Attention / Danger !!! No insulation behind the side-airbags (fig. “B”) Important: No insulation material behind - loudspeaker - door latch lever - drill ahole for the installation clip (fig. A) fig.: example of a car door Important tip: the use of woofer in the door lining may cause vibrations which lead to annoying rattle noises in the car door Preventive measurements against vibration noise: • use our self-adhesive insulation fleece (art.no.: 27000) or a foam material for the backside of the door lining (see fig. above) or • stabilize the backside of the door lining by means of a special material (Glass Fibre Filler or stiffening material) important: keep the cut-outs for the door-airbags and speakers open • affix the *backside of the inner door metal with self-adhesive asphalt mats (see fig. * ) • by knocking on the car door, vibrations caused by mechanic parts (e.g. Bowden pull wire etc. ) and wiring harness may be found out. Cover these parts with foamed material, felt or something like that • cut off overlapping cable tie (rattle noise) • adhere felt or foamed material under the original wiring harness moisture protection foil front side of inner door metal door metal outside = back side of the inner door metal fig.: example of a car door Installation of the speaker’s grill Precisely align and carefully press grill into the Velcro fasteners. ☞ The Velcro fastener makes a crackling sound when it is closed correctly. Our Tip: If the panel cannot be pressed on completely at some points. . . Cause: Solution: the special form at these points and the resulting differences inmaterial cross section of the grill. the distance can be levelled out with spacers 3 under the Velcro disc. (Spacers included with the screw kit) ② self-adhesive Velcro-strip ① Velcro fastener ③ Washer M4 ø 20 as spacer 6. Removing the grills: The Velcro fasteners stick together very strongly! The grills can be removed anytime by carefully lifting them off. Please, avoid any way of forceful yanking at the grills. It could break! Self-help and fault diagnosis The following notes serve to help troubleshoot and eliminate faults or malfunctionson your own. If the following measures are not effective, please call us. Info-Hotline Tel. 0049-7158/95699-0 What can it be if ... possible cause/ solution ..it doesn’t sound right · wrong polarity on the subwoofers (see „speaker connection“) · crosover circuit attached wrong (see „wiring diagram speaker connection“) · door lining and moisture protection foil not cut out (see. „installation of teh door lining“ and „installation of the speakers grill“) · ampilifier doesn’t have enough power (see. „technical details“) · amplifier connection ...it doesn’t fit correctly · door panel customization (see „handling of the door lining“) · installation of the panels on the door lining .....grills do not hold observe notes (see „installation of the speakers grill“) vibrations observe notes (see „insulation of the door lining“)