BMW 82 82 0 304 135 Installation Instructions Manual

BMW
Brand
BMW
Model
82 82 0 304 135
Type
Installation Instructions Manual

This manual is also suitable for

Retrofit / Installation kit No. 82 82 0 304 134 (others see cover sheet)
Installation Instructions No. 01 29 0 141 494 Issue date: 05.2003
Retrofit Kit BMW DVD System
BMW 5 Series Saloon (E
39)
Technical and electrical knowledge required
The installation time is approx. 4.5 - 5.5 hours but this may vary depending on the condition of the car and
the equipment in it.
Retrofit / Installation kit No.
82 82 0 304 134
82 82 0 304 135
82 82 0 304 136
82 82 0 304 137
0
Parts and Accessories
Installation Instructions
039 0213 B
EN/2
Retrofit / Installation kit No. 82 82 0 304 134 (others see cover sheet)
Installation Instructions No. 01 29 0 141 494 Issue date: 05.2003
Contents
Section Page
1. Important information for the installation of the DVD system . . . . . . . . . . . . . . . . . . 3
2. Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5. To install the roof hoop (cars with a sunroof) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6. To install the roof hoop (cars without a sunroof) . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7. To retrofit an earth connection (only required
if there is no earth post connection X10305 below the left tail light). . . . . . . . . . . . . 13
8. To install and route the power supply cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9. To install the DVD console (cars with an alarm system) . . . . . . . . . . . . . . . . . . . . . . 18
10. To install the DVD console (cars without an alarm system) . . . . . . . . . . . . . . . . . . . 20
11. Concluding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
12. Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
EN/3
Retrofit / Installation kit No. 82 82 0 304 134 (others see cover sheet)
Installation Instructions No. 01 29 0 141 494 Issue date: 05.2003
1. Important information for the installation of the DVD system
These installation instructions are primarily designed for use within the BMW dealership
organisation and by authorised BMW service companies.
In any event the target group for these installation instructions is specialist personnel trained on
BMW cars with the appropriate specialist knowledge.
All work must be completed using the latest BMW repair manuals, circuit diagrams, servicing
manuals and work instructions in a rational order using the prescribed tools (special tools) and
observing current health and safety regulations.
Ensure that the cables/lines are not kinked or damaged as you install them in the car. The costs
incurred as a result of this will not be reimbursed by the BMW AG.
Additional cables/lines that you install must be secured with cable ties.
If the specified PIN chambers are occupied, bridges, double crimps or twin-lead terminals must
be used.
All the figures show LHD cars, proceed in exactly the same way on RHD cars.
Inform the car owner that the DVD system has a separate fuse. The fuse holder is located
at the rear left of the boot in the vicinity of the retrofit plug connector
X322
. Check the fuse
first if the DVD system does not work. If it has blown, it must be replaced by a new
3 A
fuse
.
If the car has an alarm system, inform the owner that optimum function of the alarm system
can only be guaranteed when the DVD monitor is folded in.
Depending on the equipment in the car, 2 part numbers (installation kit
and
DVD
system) must be ordered using the electronic parts catalogue (EPC) for the installation of
the DVD system.
All holes drilled must be treated with anti-corrosion measures set out in BMW
specifications.
Subject to technical modifications
Required tools and equipment
MoDiC III or DIS Cable lamp
1/4 inch socket set Angle cutter
Set of Torx sockets Universal knife
Set of Philips screwdrivers Textile adhesive tape
Set of flat screwdrivers Dust extractor
Set of drill bits Threaded rivet pliers
Conical counter-sink Disconnection tool
Drill
EN/4
Retrofit / Installation kit No. 82 82 0 304 134 (others see cover sheet)
Installation Instructions No. 01 29 0 141 494 Issue date: 05.2003
2. Preparations
0
The TIS AW numbers identified with an "*" in the Preparations chapter are not 100 % relevant
and therefore should not be adopted completely!
TIS instruction
No.
Print out error memory
---
Disconnect the battery 12 00 ...
Remove the ultrasonic module of the alarm system
(if fitted)
65 75 570
Remove the attachment frame for the ultrasonic module
(if fitted)
---
Remove the headlining (cars without a sunroof)
(Only unfasten the A, B and C pillars in the upper area)
*51 44 001
Remove the headlining (cars without a sunroof)
(Only unfasten the A, B and C pillars in the upper area)
*51 44 011
Remove the rear seat bench 52 24 005
Remove the rear seat backrest (cars without a through-load facility only) 52 24 010
Remove the left backrest side section on the rear seat backrest
(cars with a through-load facility only)
52 26 008
Remove the boot floor *51 47 101
Remove the rear left boot trim *51 47 ...
Remove the left boot trim *51 47 ...
Remove the left tail light
(only cars without earth post X10305 below the left tail light)
63 21 180
EN/5
Retrofit / Installation kit No. 82 82 0 304 134 (others see cover sheet)
Installation Instructions No. 01 29 0 141 494 Issue date: 05.2003
3. Parts list
0
c
Bedienungsanleitung
d
039 0214 B
EN/6
Retrofit / Installation kit No. 82 82 0 304 134 (others see cover sheet)
Installation Instructions No. 01 29 0 141 494 Issue date: 05.2003
Legend
0
The two DVD consoles marked with an asterisk (*) are not included in the installation kit and must
be ordered depending on the equipment in the car.
All other parts are included in the relevant installation kit according to the equipment in the car.
APower supply cable
BAdapter cable for alarm system
(only for cars with an alarm system pre-installed on the DVD console)
1 DVD console (cars with an alarm system)*
2 DVD console (cars without an alarm system)*
3Cover for ultrasonic module (only cars with an alarm system)
4Roof hoop (cars with a sunroof)
5Roof hoop (cars without sunroof)
6Velcro tape (300 mm) (2x)
7Damping strip (10x)
8 Threaded rivet M5x13.5 (6x)
9Hexagonal screw M5x16 (6x)
10 Bodywork washer M5 (6x)
11 Allen bolt M5x20 mm (2x)
12 Cable tie (6x)
13 Hexagonal screw with collar M6x20
(only cars without an earth post X10305)
14 Bodywork washer Ø 6.3 mm
(only cars without an earth post X10305)
15 Nut with collar M6 (2x)
(only cars without an earth post X10305)
16 1-pin socket casing (3x, contained in item A)
17 Remote control for DVD console
18 Infra red headphones (2x)
19 Owner’s manual
20 Rattle guard (only cars with an alarm system)
EN/7
Retrofit / Installation kit No. 82 82 0 304 134 (others see cover sheet)
Installation Instructions No. 01 29 0 141 494 Issue date: 05.2003
4. Connection overview
0
0
0
0
0
The X designations marked with an asterisk (*) are only valid for this diagram and do not refer to
the BMW after sales circuit diagrams.
Item Description Signal
Cable colour /
Cross-section
Connection location in the car
Abbreviation /
Slot
APower supply cable
--- --- --- ---
A1 Grey 20-pin socket casing
--- ---
to DVD console X001*
A2 Twin-lead terminal socket casing
and 1-pin black plug casing
Tl. 30
RT/GN
to white 12-pin socket casing,
PIN1
in boot rear left
X322
A3 Twin-lead terminal socket casing
and 1-pin black plug casing
Te r minal R VI/WS to white 12-pin socket casing,
PIN2
in boot rear left
X322
A4 Twin-lead terminal socket casing
and 1-pin black plug casing
Tl. 58g GR/RT to white 12-pin socket casing,
PIN5
in boot rear left
X322
A5 Cable lug, 6 mm in diameter Tl. 31 BR to earth post below left tail light X10305
A6 Fuse holder
(3 A fuse)
Tl. 30
---
Fusing of the DVD system
---
Item Description Signal
Cable colour
/ Cross-
section
Connection location in the car
Abbreviation /
Slot
B Alarm system adapter (pre-
installed on DVD console)
--- --- --- ---
B1 Black 4-pin
plug casing
--- ---
to connection plug for the ultrasonic
module in the headlining
X1582
B2 Black 4-pin
socket casing
--- ---
to ultrasonic module of the alarm
system
X001*
039 0215 B
039 0216 B
EN/8
Retrofit / Installation kit No. 82 82 0 304 134 (others see cover sheet)
Installation Instructions No. 01 29 0 141 494 Issue date: 05.2003
5. To install the roof hoop (cars with a sunroof)
0
0
0
0
0
Direction of arrow = Driving direction.
Place the roof hoop (4) in the car as illustrated.
0
Direction of arrow = Driving direction.
Align the roof hoop (4) so the gap from the front
edge of the roof hoop (4) to the sunroof cut-out (30)
is dimension
a
.
Dimension
a
= 27 mm
0
Push the roof hoop (4) upwards on the
left-hand
side of the car and mark the fastening holes (30).
0
Push the roof hoop (4) upwards on the
right-hand
side of the car and mark the fastening holes (30).
039 0217 B
4
4
30
a
039 0218 B
4
30
039 0219 B
4
30
039 0220 B
EN/9
Retrofit / Installation kit No. 82 82 0 304 134 (others see cover sheet)
Installation Instructions No. 01 29 0 141 494 Issue date: 05.2003
5. To install the roof hoop (cars with a sunroof)
0
0
0
0
0
0
The figure shows installation of the threaded
rivets on the left-hand side of the car.
Proceed in exactly the same way on the right-
hand side.
When drilling, use a vacuum cleaner to suck
up all chips and swarf.
Drill the holes, 7 mm diameter, at the markings
(30).
Deburr the edges of the holes.
Push threaded rivets M5x13.5 (8) into the holes
and fix in place with threaded rivet pliers.
0
Magnified view shows section A-A.
Stick a Velcro strip 300 mm (6) onto the retaining
lug (30) on the roof hoop (4) as shown in the figure.
(Cut off any excess length.)
0
Cut through one damping strip (7) lengthways.
Cut through two damping strips (7) sideways.
8
30
039 0221 B
6
A
A
30
4
4
6
039 0314 B
039 0222 B
7
1x
2x
7
EN/10
Retrofit / Installation kit No. 82 82 0 304 134 (others see cover sheet)
Installation Instructions No. 01 29 0 141 494 Issue date: 05.2003
5. To install the roof hoop (cars with a sunroof)
0
0
0
0
0
Glue seven complete damping strips (7) onto the
roof hoop (4) from above.
Trim off the two lower complete damping strips (7)
along the roof hoop (4).
Also glue the lengthways cut damping strips (30)
and the sideways cut damping strips (31) onto the
roof hoop (4).
0
The figure shows installation of the roof hoop
on the left-hand side of the car. Proceed in
exactly the same way on the right-hand
side.
Place the roof hoop (4) in the car.
Push the roof hoop (4) upwards and use two
hexagonal screws M5x16 (9) and two bodywork
washers (10) to screw it firmly onto the inserted
threaded rivets (8).
0
Direction of arrow = Driving direction.
Using a sharp knife,
carefully
cut out the
headlining (30) to the dimensions
a
,
b
,
c
,
d
,
e
and
f
.
Dimension
a
= 130 mm
Dimension
b
= 75 mm
Dimension
c
= 195 mm
Dimension
d
= 320 mm
Dimension
e
= 70 mm
Dimension
f = 220 mm
7
4
7
31 31
30
039 0223 B
9
4 4
8
10
039 0224 B
a
e
f
c
b
b
d
30
ø70mm
ø70mm
ø40mm
039 0225 B
EN/11
Retrofit / Installation kit No. 82 82 0 304 134 (others see cover sheet)
Installation Instructions No. 01 29 0 141 494 Issue date: 05.2003
6. To install the roof hoop (cars without a sunroof)
0
0
0
0
0
The figure shows the roof area behind the B
pillar on the left-hand side of the car. Proceed
in exactly the same way on the right-hand
side.
Unclip the mounting point for the rear handle (30).
0
Direction of arrow = Driving direction.
Place the roof hoop (5) in the car as illustrated.
Place the roof hoop (5) on the left-hand side of the
car with its front edge against the fixing lug for the
head airbag (30), push it upwards and mark the
fastening holes (31).
0
Direction of arrow = Driving direction.
Place the roof hoop (5) in the car as illustrated.
Place the roof hoop (5) on the right-hand side of
the car with its front edge against the fixing lug for
the head airbag (30), push it upwards and mark the
fastening holes (31).
0
The figure shows installation of the threaded
rivets on the left-hand side of the car.
Proceed in exactly the same way on the right-
hand side.
When drilling, use a vacuum cleaner to suck
up all chips and swarf.
Drill the holes, 7 mm diameter, at the markings
(30). Deburr the edges of the holes. Push threaded
rivets M5x13.5 (8) into the holes and fix in place
with threaded rivet pliers.
30
039 0226 B
30
31
5
039 0227 B
30
31
5
039 0228 B
30
31
8
039 0229 B
EN/12
Retrofit / Installation kit No. 82 82 0 304 134 (others see cover sheet)
Installation Instructions No. 01 29 0 141 494 Issue date: 05.2003
6. To install the roof hoop (cars without a sunroof)
0
0
0
0
0
Magnified view shows section A-A.
Stick a Velcro strip 300 mm (6) onto the retaining
lug (30) on the roof hoop (5) as shown in the
diagram. (Cut off any excess length.)
0
Glue eight damping strips (7) onto the roof hoop (5)
from above.
Then trim off four damping strips along on the roof
hoop (5) as shown in the figure.
0
The figure shows installation of the roof hoop
on the left-hand side of the car. Proceed in
exactly the same way on the right-hand
side.
Push the roof hoop (5) upwards and use three
hexagonal screws M5x16 (9) and three bodywork
washers (10) to screw it firmly onto the inserted
threaded rivets (8).
0
Direction of arrow = Driving direction.
Using a sharp knife, carefully cut out the
headlining (30) to the dimensions a, b, c, d, e and
f.
Dimension a = 75 mm
Dimension b = 710 mm
Dimension c = 770 mm
Dimension d = 890 mm
Dimension e = 70 mm
Dimension f = 220 mm
5
A
A
6
30
6
30
5
039 0230 B
7
5
7
039 0231 B
8
5
9
10
039 0232 B
b
e
f
c
a
a
d
30
ø70mm
ø70mm
ø40mm
039 0233 B
EN/13
Retrofit / Installation kit No. 82 82 0 304 134 (others see cover sheet)
Installation Instructions No. 01 29 0 141 494 Issue date: 05.2003
7. To retrofit an earth connector (only required if there is no earth post X10305
below the left tail light)
0
0
0
Only cars up to production date 9/00
Risk of damage. Before drilling the hole
ensure that the cable and plug fastenings are
unclipped and the cables are removed from
the drilling area to prevent their being
damaged.
Centrepunch the position of the hole (30).
Dimension a = 22 mm
Dimension b = 17 mm
Remove the paint and primer in the grey area (31)
over a diameter of 20 mm around the position of
the hole (20) on the front and rear of the tail light
unit (32).
Remove the area (31) in a diameter of 20 mm
around the position of the hole (20) on the front and
rear of the tail light unit (32).
The panel must be bare in the grey area (31), to
ensure that perfect contact is possible.
Drill the hole with a 6 mm drill bit and vacuum up
any chips and swarf.
Then deburr the edges of the hole.
0
Only cars up to production date 9/00
Insert the hexagonal screw with collar (13) from the
rear into the hole (30) drilled previously and secure
it with a nut M6 (15).
If installing an earth connection cable (31)
subsequently, make sure that the bodywork
washer (14) is fitted first, then the cable lug of the
earth connection cable (31).
Then screw on the earth connection cable (31)
with the second nut M6 (15) (the earth connection
cable (31) must point towards the centre of the
car).
After securing the parts, treat all of them with
the anti-corrosion measures set out in the
BMW standard.
039 0235 B
039 0236 B
EN/14
Retrofit / Installation kit No. 82 82 0 304 134 (others see cover sheet)
Installation Instructions No. 01 29 0 141 494 Issue date: 05.2003
0
0
Only cars up to production date 9/00
The figure shows the final installation position of an
earth connection cable (30).
The earth connection cable (30) must point
to the centre of the car.
039 0237 B
EN/15
Retrofit / Installation kit No. 82 82 0 304 134 (others see cover sheet)
Installation Instructions No. 01 29 0 141 494 Issue date: 05.2003
7. To retrofit an earth connector (only required if there is no earth post X10305 below the left
tail light)
0
0
0
0
Only cars up to production date 9/00
The figure shows the lamp holder of the left
tail light.
Mark the drilling position (30) on the left lamp
holder (31) with dimension a and b, then use a step
drill bit to drill the hole out to a diameter of 18 mm.
Dimension a = 17 mm
Dimension b = 11 mm
Then deburr the hole and install the left tail light
and the left lamp holder (31).
0
Only cars after production date 9/00
Risk of damage. Before drilling the hole
ensure that the cable and plug fastenings are
unclipped and the cables are removed from
the drilling area to prevent their being
damaged.
Centrepunch the position of the hole (30).
Dimension a = 19 mm
Dimension b = 17 mm
Remove the body paint and primer from the grey
area (31) in a diameter of 20 mm around the
position of the hole (30) on the front and rear of the
tail light unit (32).
The panel must be bare in the grey area (31), to
ensure that perfect contact is possible.
Drill the hole with a 6 mm drill bit and vacuum up
any chips and swarf.
Then deburr the edges of the hole.
0
Only cars after production date 9/00
Insert the hexagonal screw with collar (13) from the
rear into the hole (30) drilled previously and secure
it with a nut M6 (15).
If installing an earth connection cable (31)
subsequently, make sure that the bodywork
washer (14) is fitted first, then the cable lug of the
earth connection cable (31).
Then screw on the earth connection cable (31)
with the second nut M6 (15) (the earth connection
cable (31) must point downwards).
After securing the parts, treat all of them with
the anti-corrosion measures set out in the
BMW standard.
039 0238 B
32
a
b
30
31
039 0239 B
039 0240 B
30
15
15
14
13
31
EN/16
Retrofit / Installation kit No. 82 82 0 304 134 (others see cover sheet)
Installation Instructions No. 01 29 0 141 494 Issue date: 05.2003
7. To retrofit an earth connector (only required if there is no earth post X10305 below the left
tail light)
0
0
0
Only cars after production date 9/00
The figure shows the final installation position of an
earth connection cable (30).
The earth connection cable (30) must point
downwards.
30
039 0241 B
EN/17
Retrofit / Installation kit No. 82 82 0 304 134 (others see cover sheet)
Installation Instructions No. 01 29 0 141 494 Issue date: 05.2003
8. To install and route the power supply cable
0
0
0
0
0
Direction of arrow = Driving direction.
Use textile adhesive tape (30) to attach the branch
A1 of the power supply cable A, to the roof hoop
(4/5), as shown in the figure (excess length about
200 mm).
Then route the power supply cable A with
branches A2 to A6 into the boot on the left.
Only for cars with an alarm system
Use textile adhesive tape (30) to attach the
connection cable (31) for the ultrasonic module.
0
Route the power supply cable A along the
standard wiring harness to the retrofit plug
connector X322 in the boot on the left and use
textile adhesive tape (30) or the cable ties already
in the vehicle to attach it.
0
Disconnect retrofit plug connector X322.
Unlock the white 12-pin socket casting (30) of the
retrofit plug connector X322.
Disconnect the socket casing slot PIN1, red/green
cable.
Connect the socket contact of the branch A2, red/
green cable, into the empty slot PIN1
of the 12-pin socket casing (30).
Connect the disconnected socket contact, red/
green cable, into the black socket casing (16).
Connect the black socket casing (16) to the plug
casing of the branch A2, red/green cable.
039 0242 B
4/5
A2-A6
30
30
31
A1
A
30
A
A
039 0243 B
A4
A3
A2
X322
30
16
039 0244 B
EN/18
Retrofit / Installation kit No. 82 82 0 304 134 (others see cover sheet)
Installation Instructions No. 01 29 0 141 494 Issue date: 05.2003
8. To install and route the power supply cable
0
0
0
Follow the same procedure as for branch A2 with
branches A3 and A4.
Branch A3, violet/white cable, slot PIN2.
Branch A4, grey/red cable, slot PIN5.
Then lock the 12-pin socket casing (30) and re-
connect the retrofit plug connector X322.
The fuse holder A6 (3 A fuse) is used for protecting
the DVD system.
0
Route the branch A5, cable eyelet Ø 6 mm, brown
cable, to the existing or installed earth post
X10305 below the left tail light and screw it on
tightly.
Tie back excess lengths and attach the power
supply cable A using cable ties.
Then install the headlining in the car.
A2
A4
A3
X322
30
A6
039 0245 B
A5
X10305
039 0246 B
EN/19
Retrofit / Installation kit No. 82 82 0 304 134 (others see cover sheet)
Installation Instructions No. 01 29 0 141 494 Issue date: 05.2003
9. To install the DVD console (cars with an alarm system)
0
0
0
0
0
Magnified view shows section A-A.
Glue the Velcro strip (6) onto the retaining plate
(30) of the DVD console (1) as shown in the figure.
(Cut off any excess length.)
0
Route the branch A1 of the power supply cable A
and the connection plug for the ultrasonic module
(30) through the opening (31) in the headlining (32).
0
Connect the branch A1 to the connection plug (30)
of the DVD console (1).
Connect the connection plug for the ultrasonic
module (31) to the branch B1 of the alarm system
adapter cable B.
Glue the rattle guard (20) onto the cable so the
plug connector (31+B1) is enveloped.
0
As you are attaching the DVD console,
ensure that you do not jam or damage the
connection cables.
Push the DVD console (1) and the retaining plate
(30) into the retaining lug (31) on the roof hoop.
If the fit between the retaining plate (30) and the
retaining lug (31) is not sufficiently secure, bend
the retaining lug (31) or the retaining plate (30)
slightly.
6
1
30
AA
6
30
1
039 0247 B
A1
32
30
31
039 0248 B
A1
1
B
B1
30
31
20
039 0249 B
1
30
31
039 0250 B
EN/20
Retrofit / Installation kit No. 82 82 0 304 134 (others see cover sheet)
Installation Instructions No. 01 29 0 141 494 Issue date: 05.2003
9. To install the DVD console (cars with an alarm system)
0
0
0
0
0
Fold down the monitor (30).
Use two Allen bolts M5x20 (11) to screw the DVD
console (1) onto the roof hoop, as shown in the
figure.
0
Note the driving direction arrows on the
ultrasonic module (30) and the cover of the
ultrasonic module (3).
Clip the supplied ultrasonic module (30) into the
black cover of the ultrasonic module (3).
0
The figure shows the DVD console from
below.
Connect the branch B2 of the alarm system
adapter cable B onto the connection plug (30) of
the ultrasonic module (31).
Note the driving direction arrows.
Clip the cover of the ultrasonic module (3) onto the
retaining frame (32).
1
30
11
039 0251 B
30
3
039 0252 B
3
31
30
32
B2
B
039 0253 B
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BMW 82 82 0 304 135 Installation Instructions Manual

BMW
Brand
BMW
Model
82 82 0 304 135
Type
Installation Instructions Manual
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