BMW 82 44 0 007 417 Installation Instructions Manual

Brand: BMW

Model: 82 44 0 007 417

Type: Installation Instructions Manual

F 53 0139 EVA

BMW Parts and Accessories

Installation Instructions

Retrofit/Installation Kit no. 82 44 0 007 417 Date: 03.2001

Installation Instructions no. 01 29 0 138 198

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. 82 44 0 007 417

Contents

Chapter Page

1. Preparatory work on the vehicle .................................................................................. 3

2. Parts kit ...................................................................................................................... 4

3. Overview of supplementary wiring harness .................................................................. 6

4. Installation diagram...................................................................................................... 7

5. Install supplementary wiring harness .......................................................................... 8

6. Mount roof headlights..................................................................................................13

7. Function test of roof headlights and adjustment of roof headlights..............................16

8. Paint specifications ......................................................................................................17

9. Circuit diagram of supplementary wiring harness ........................................................18

Retrofit/Installation Kit no. 82 44 0 007 417 Date: 03.2001

Installation Instructions no. 01 29 0 138 198

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 left-

hand 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.

EN/1

Retrofit/Installation Kit no. 82 44 0 007 417 Date: 03.2001

Installation Instructions no. 01 29 0 138 198

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 10 mm

Marker pen

Tape measure

Prick punch

Hammer

Unpinning tool

1/4 inch reversible ratchet with hexagonal insert SW 8, SW 10

Long extension

Torx inserts TX-10; ZX-20,TX-40

Fork wrench SW 10 mm

Torque wrench

Side-cutting pliers

Crimping pliers

Long thin wire (length approx. 1000 mm)

Phillips screwdrivers, medium size

Flat-tip screwdrivers, small size

Zinc dust paint

Loctite adhesive 270

Sikaflex 255 FC

Cyanoacrylate adhesive (BMW part no. 81 22 9 407 143)

Retrofit/Installation Kit no. 82 44 0 007 417 Date: 03.2001

Installation Instructions no. 01 29 0 138 198

EN/2

1. Preparatory work on the vehicle

TIS AW No.

Disconnect battery

Dismantle console at headlining, front 51 44 020

Completely dismantle roof light 63 31 000

Dismantle trim panel for roof pillar, front (A-pillar)

(dismantle left and right trim panel) 51 43 201

Dismantle sun visor and hinge bracket

(dismantle left and right sun visor) 51 16 080

Dismantle grab handle, front

(dismantle left and right grab handle) 51 16 480

Dismantle trim panel for door pillar (bottom)

(dismantle left and right door pillar) 51 43 150

Dismantle glove box 51 16 360

Remove spare wheel

Dismantle flap in boot, right 51 47 172

Dismantle boot wheel-arch trim panel, right 51 47 161

Retrofit/Installation Kit no. 82 44 0 007 417 Date: 03.2001

Installation Instructions no. 01 29 0 138 198

EN/3

Retrofit/Installation Kit no. 82 44 0 007 417 Date: 03.2001

Installation Instructions no. 01 29 0 138 198

2. Parts kit

EN/4

F 53 0169 EVA

RHF

LHF

Zusatzscheinwerfer auf Dach

BMW X5

BMW 5er touring,

Bedienungsanleitung

Installation information

Informations concernant le montage

Montage-informatie

Monteringsinformation

Informazioni per il montaggio

Información de montaje

The additional headlights must not

be used on public roads.

01 29 0 136 411

2. Parts kit

a Supplementary wiring harness

b Quick connector (2x)

c Blade receptacle (4x)

d Switch of roof headlights (1x)

e Frame for switch of roof headlights (1x)

f Front railing-foot of roof headlight, left (1x)

g Front railing-foot of roof headlight, right (1x)

h Seal moulding with through hole, left (1x)

i Seal moulding with through hole, right (1x)

j Half liner (4x)

k Allen key 3 mm (1x)

l Instruction manual (1x)

Not included in the parts kit:

m Headlight insert (2x)

n Housing (2x)

o Stabilising ring (2x)

p Rubber grommet (2x)

q Warning sticker (for US market only)

r Special tool (opening spatula) (1x)

s Covering cap (2x)

EN/5

Retrofit/Installation Kit no. 82 44 0 007 417 Date: 03.2001

Installation Instructions no. 01 29 0 138 198

F 53 0147 EVA

BC D

JKL

3. Overview of supplementary wiring harness

Retrofit/Installation Kit no. 82 44 0 007 417 Date: 03.2001

Installation Instructions no. 01 29 0 138 198

EN/6

Supplementary wiring harness

Open contacts

6-pole socket housing

Open contacts

Black relay on base

(NSL module)

Blue relay on base

Green relay on base

Open contact

Connector with twin-lead

terminal

Ring terminal

Roof headlight, left

Plug into switch of roof headlights

Roof headlight, right

Fasten at side of the relay carrier

Plug into relay carrier

Fasten at side of the relay carrier

Connect with quick connector at main wiring

harness with cable colour GN/WS

Connect with quick connector at joint

connector box with cable colour GR/RT

Plug unpinned cable pin 13, light check

module, cable colour WS/BL, in socket

housing. Plug cable with cable colour WS/BL

in light check module, pin 13.

At power distribution box, left side of vehicle,

spare wheel recess

At earth pin at joint connector

Item Package / Designation

Cable colour Connection point in vehicle

X6501

X1879

X6501

X1856

X43

X1209

X6830

X806

X343S

X3245

X10012

Code designation/

plug-in place

red

brown

red

brown

brown/black

red/green

green

yellow/black

yellow/grey

blue

yellow/black

red/green

2xred

white/blue

brown/black

2xred

green/white

grey/red

white/blue

red

brown

F 53 0141 EVA

4. Installation diagram

Retrofit/Installation Kit no. 82 44 0 007 417 Date: 03.2001

Installation Instructions no. 01 29 0 138 198

EN/7

Key

1 Roof headlights

2 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. 82 44 0 007 417 Date: 03.2001

Installation Instructions no. 01 29 0 138 198

Undo the Torx screws (1) over the whole roof

railing (3 Torx screws on each side) (2) and lift the

roof railing (2) off.

5. Install supplementary wiring harness

F 53 0143 EVA

F 53 0155 EVA

280mm

30mm

Ø10 mm

F 53 0168 EVA

Care should be taken to see that the roof

outer skin panel (1) and the two reinforcement

plates lying underneath (2 and 3) are drilled

through.

All drill holes should be carefully deburred

and treated with BMW customary corrosion-

protection measures.

In accordance with the given measurements,

mark the centre of the drill hole for cable feed-

through (4) with a marker pen. Lightly centre-

punch the centre of the drill hole for cable feed-

through (4). Make the drill hole for cable feed-

through (4) with a drill Ø 10 mm.

Make the aperture (1) for the switch of the roof

headlights (d) in accordance with the diagram

specifications and the following measurements

on the roof console (2).

M1: 23 mm M2: 160 mm

M3: 43.5 mm M4: 21.5 mm

Stick the frame for the switch of the roof

headlights (e) in the aperture (1) with

cyanoacrylate adhesive (for verification refer to

BMW parts service, part no. 81 22 9 407 143).

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

0168 EVA.This prohibits the use of the auxiliary

headlights on the public highway.

EN/8

Retrofit/Installation Kit no. 82 44 0 007 417 Date: 03.2001

Installation Instructions no. 01 29 0 138 198

The supplementary wiring harness (a) is installed

under the fuse carrier.

Remove the joint connector box (1) from the relay

carrier (2). Dismantle the relay carrier (2).

5. Install supplementary wiring harness

F 53 0146 EVA

EN/9

F 53 0148 EVA

Insert branch cable F X43, blue relay with base,

from the rear into a free relay plug-in place in the

relay carrier (1).

At joint connector box X806 (1), 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 (2).

F 53 0149 EVA

F 53 0150 EVA

Out of the main wiring harness X6830 (1), select

a cable of cable colour green/white (terminal 15)

of 0.5 mm

or 0.75 mm

and fasten branch

cable H, cable colour green/white, to the cable of

cable colour green/white (terminal 15) of the

main wiring harness X6830 (1) with the aid of a

quick connector (2).

Retrofit/Installation Kit no. 82 44 0 007 417 Date: 03.2001

Installation Instructions no. 01 29 0 138 198

5. Install supplementary wiring harness

F 53 0151 EVA

F 53 0152 EVA

Pull off the upper black connector X12 (1) of the

light check module and select the cable of cable

colour white/blue (pin 13). 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

X12 (1) of the light check module (pin 13).

Plug the 1-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 X1209, green relay, and

branch cable E X1856, black relay, with cable

ties at a suitable place behind the joint

connector box (1).

EN/10

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

2.5 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 (1) to the earth pin

X10012 (2) and connect it .Tie back branch

cable L and fasten with cable ties.

F 53 0170 EVA

F 53 0144 EVA

Install branch cable K, cable colour red, along

the main wiring harness to the power distribution

box X3245 (1) on the left-hand side of the

vehicle in the spare wheel recess. Connect the

ring terminal (2) coming from branch cable K to

the power distribution box B+ X3245 (1).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.

Retrofit/Installation Kit no. 82 44 0 007 417 Date: 03.2001

Installation Instructions no. 01 29 0 138 198

5. Install supplementary wiring harness

F 53 0154 EVA

CB+D

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.

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 (1).

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 (2) 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.

EN/11

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 (1) 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 (1).

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 (2).

F 53 0156 EVA

B+D

F 53 0157 EVA

Install branch cable B, cable colour red and

brown, for the right roof headlight behind the roof

liner contour (1).

In vehicles with sunroof, loosely fasten branch

cable B with a cable tie to the sunroof drainage (2)

(only applies to the right-hand side of the vehicle).

Remove the rubber bung (3) from the roof side-

frame.

Retrofit/Installation Kit no. 82 44 0 007 417 Date: 03.2001

Installation Instructions no. 01 29 0 138 198

5. Install supplementary wiring harness

F 53 0158 EVA

When working in the area of the roof side-

frame, 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 (1, 4, 5 and 2).

Guide a thin wire from the roof outer skin panel

through the drill holes (1, 4, 5 and 2) to the roof

side frame in the vehicle interior. With the aid of

the thin wire, thread branch cable B through the

drill holes (2, 5, 4 and 1) to the outside. Seal drill

hole (1) with Sikaflex 255 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 (1, 4, 5 and 2) without chafing (see

magnification).

EN/12

Retrofit/Installation Kit no. 82 44 0 007 417 Date: 03.2001

Installation Instructions no. 01 29 0 138 198

Undo the Torx screw (1), connecting the front

railing-foot (2) with the central railing part (3),

take it out and keep it. Draw the front railing

foot (2) out of the central railing part (3).

Remove the seal (4) from the front railing foot (2)

and keep it safe.

6. Mount roof headlights

F 53 0159 EVA

2 4 3

F 53 0160 EVA

F 53 0161 EVA

1 2

3 4

F 53 0162 EVA

Push the seal (1) 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 (2) and bring the drill holes (3 and 4)

into alignment. Dampen the Torx screw (5) with

Loctite adhesive 270 and screw together the

front railing-foot of the roof headlight, left, (f) and

the central railing part (4) with a torque spanner

to 9.2 Nm.

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 (1) and at the same time thread branch

cable B through the additional hole in the seal

moulding (h).The sealing (2) 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 (2).

Place the roof railing (3) on the adapter of the

roof railing (1) 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 (1). Make sure when

doing so that all seal mouldings are correctly

positioned. Lightly screw the roof railing (1) to all

three roof-railing adapters with the Torx screws (2).

Press the roof railing (1) 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 (2) with a torque spanner to 22.3 Nm.

Screw down the roof-railing adapters of front and

rear in the same way with a torque spanner to

22.3 Nm.

EN/13

Retrofit/Installation Kit no. 82 44 0 007 417 Date: 03.2001

Installation Instructions no. 01 29 0 138 198

Insert the stabilising ring (1) in the housing (n).

6. Mount roof headlights

F 53 0163 EVA

F 53 0164 EVA

F 53 0166 EVA

2 B

Thread branch cable B through the housing

base (1). Place two half-liners (j) against the

housing base (1) as shown in the magnification.

Insert the housing (n) with the half-liners (j) in the

base support (2) in such a way that the half-

liners (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.

Pull the cable ends (1) of branch cable B through

the rubber grommet (p) and fit the rubber

grommet (p) in the opening of the housing

base (2). Shorten the cable ends (1) to length for

fitting the headlight insert and crimp on to each

of the cable ends (1) a blade receptacle (c).

EN/14

Retrofit/Installation Kit no. 82 44 0 007 417 Date: 03.2001

Installation Instructions no. 01 29 0 138 198

The "TOP" marking (1) should always point to

the top.

Connect the cable (2), 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 X1879

in the roof console. Install the roof console in the

roof liner.

6. Mount roof headlights

F 53 0165 EVA

EN/15

Retrofit/Installation Kit no. 82 44 0 007 417 Date: 03.2001

Installation Instructions no. 01 29 0 138 198

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.

7. Function test of roof headlights and adjustment of roof headlights

F 53 0140 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: 1.68 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).

EN/16

Retrofit/Installation Kit no. 82 44 0 007 417 Date: 03.2001

Installation Instructions no. 01 29 0 138 198

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 541-30

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 1K-Plastics Primer 934-0

Glasurit 2K Plastics Primer 934-200 with Glasurit supplement for Plastics Primer 934-100.

Painting

The topcoat with a 2-part topcoat or a 2-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 2K topcoat 22

Metallic paint: e.g. Glasurit two-coat topcoat Metallic / Uni 55

8. Paint specifications

EN/17

31E

286

KL_31

Signal

KL_15

S2069

X806

LCM

Lastkreis

K43A5

25 894

A71

X12

S_NSL

NSL_OUT

1.5

2.5

1.5

KL_15

58G

2.5

1.0

BRSW

0.75

GNWS

0.5

GEGR

0.5

BRSW

0.5

BRSW

0.5

GRRT

0.5

WSBL

0.5

BRSW

0.5

WSBL

0.5

GESW

X6501

15 A

A605

X4007

9465

2.5

RTBL

X1209

X596

X6830

X596

0.5

BRSW

X1027

0.5

GESW

X3245

KL_30

X10012

X1856

X43

X1879

F 53 0167 EVA

X6501

X343S

2.5

Retrofit/Installation Kit no. 82 44 0 007 417 Date: 03.2001

Installation Instructions no. 01 29 0 138 198

9. Circuit diagram of supplementary wiring harness

EN/18

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BMW 82 44 0 007 417 Installation Instructions Manual

BMW 82 44 0 007 417 Installation Instructions Manual

BMW 82 44 0 007 417 Installation Instructions Manual

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