EBA – 01 29 9 783 715
BMW Installation Instructions
If retrofitted, approval by the official vehicle inspection authority and an entry In the car’s documents may be necessary, depending on local legislation.
Protect all exposed metal surfaces on the body against cor rosion by applying zinc powder paint.
Tools and other equipment needed
Twist drill bits, 5 mm, 6 mm and 12 mm dia.
Stepped drill bit, 4 – 30 mm and 26 – 40 mm dia.
1/2-inch torque wrench
1/2-inch reversible ratchet
1/2-inch socket wrench inserts, 13 mm, 17 mm and 22 mm across flats
1/2-inch Allen key insert, 10 mm
1/4-inch reversible ratchet
1/4-inch socket wrench insert, 10 mm across flats
Phillips (cross-head) screwdriver
Zinc powder paint
Item Illustration Designation
I F 32 72 074 Torx special tool BMW No. 002 110
- Disconnecting battery
- Removing luggage compartment trim
- Detaching rear bumper
- Attaching cross-member
- Installing wiring harness for trailer tow hitch
- Installing additional wiring harness (models without integrated cable plug connector)
- Installing repeater light for trailer flashing turn indicators
- Changing flasher relay
- Making cutout in rear bumper
- Installing luggage compartment trim
- Attaching adhesive nose weight label
- Functional check
1. Disconnecting battery
Print out the contents of the fault memory first.
When the battery is disconnected, the fault memory is erased.
On cars with a second battery (e.g. with car telephone or in dependent fuel-burning heater), disconnect the negative lead from the second battery in the luggage compartment.
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Pull off cover (1) at the bottom right of the rear seat base. Unscrew hex bolt (2) and remove cover (3).
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Unscrew hex nut (1).
Take off washer (2).
Pull off the negative lead (3).
2. Removing luggage compartment trim
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Take out screws (1).
Remove luggage compartment trim (2).
Cars with ski bag or cold-store box:
Remove the left half of the divided luggage compartment trim.
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Take out the luggage compartment floor mat (1).
Turn the locking catches (2) through 90° and pull out. Remove the luggage compartment trim (3).
Take out the jack.
Luggage compartment trim (3) is no longer needed.
However, the new luggage compartment trim is not included in the installation kit and must be ordered separately.
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Unscrew and remove wing nuts (1, 2).
Take out the spare wheel and the jack.
Unscrew hex nuts (3, 4) from the wiring harness cover strip (5).
3. Detaching rear bumper
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Press clips (1) down and pull off trim panel (2) to the rear.
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Take out Allen screws (1) and detach the bumper (2) in the direction shown by the arrow.
4. Attaching cross-member
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Check the threads on the body elements and if necessary remove undersea! or body sealant from them.
Screw the cross-member to the body with two M 1O x 30 mm hex bolts (2) at each side of the car, without finally tightening it into position.
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Mark the six drilling points on the body at left and right with a suitably bent scriber .
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Unscrew and remove the cross-member again. Centre punch the marked points (1). Drill pilot holes with a 5 mm dia. twist drill bit and open up to the final diameter with a 12 mm dia. twist drill bit.
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Remove Bodyplast and insulating coatings from the contact areas for the inserts and the cross-members. Apply zinc powder paint to the edges of the holes and other exposed areas, to prevent corrosion.
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Cars built up to 1/89:
Mark and centre-punch the hole for the wiring harness to pass through to the power socket.
A = 118 mm (measured to the right from the centre of the body)
B = 30 mm
Drill a pilot hole at the centre-punched point with a 5 mm dia.
twist drill bit, and open up with a 26 – 40 mm stepped drill bit to 36 mm dia.
Deburr the hole and coat the edge with zinc powder paint.
Remove all metal swart from the luggage compartment with a vacuum cleaner.
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Pull wiring harness (1) for the trailer tow hitch through the hole.
Insert the rubber grommet (2).
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Cars built from 1/89 on:
Left side of car
Carefully break out the pre-formed rectangular cutout (1) next to the rear side wall (2).
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Run the trailer tow hitch wiring harness (1) from the luggage compartment through the cutout.
Insert the rubber seal (2).
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Offer up the complete cross-member (1) from below to the body floor pan, and attach (without final tightening as yet) to the threaded holes provided on the left and right sides of the car, using three M 10 x 30 mm hex bolts (2) and washers on each side of the car.
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Place the left (1) and right (2) inserts in the luggage compart ment and screw them to the cross-member with three M 8 x 25 mm hex bolts and washers at each side. Do not tighten finally as yet.
Tighten the M 10 bolts first.
Align all parts correctly, then tighten the hex bolts to the following torques:
M 8: 21.4 Nm ± 12 %
M 10: 41.8 Nm ± 12 %
5. Installing wiring harness for trailer tow hitch
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Run the trailer tow hitch wiring harness (1) to the bracket (2).
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Push sleeve (1) over power socket (2).
Attach power socket (2) with three M 5 x 30 mm screws.
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Insert six 7.5 Amp fuses (1) into the trailer electrical module (2).
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Left side of car
Offer up the trailer electrical module (1) to insert (2) as shown in the drawing, and secure firmly with hex bolts (3). Join the plug connector (4) of the car’s standard wiring harness to the matching plug (5) on the trailer tow hitch wir ing harness (6).
Attach plug (7) of the trailer tow hitch wiring harness (6) to the socket on the trailer electrical module (1), and lock in the direction of the arrow.
If the cable connector is not integrated into the standard car wiring harness on the car in question, install connecting cable No. 61 12 1 388 346.
Section 6 of these instructions does not apply to cars with integral cable connector.
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Run the trailer tow hitch wiring harness along the car’s wir ing harness as far as the left rear light.
Lift out the power supply plug (1) for the rear light and insert adapter (2) between the two halves.
6. Installing additional wiring harness (cars without in tegral cable connector)
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Pull the rear seat (1) out of its retainer in the direction shown by the arrows, and remove it.
Cars with rear seat heating:
Separate the plug connection under the rear seat.
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Cars with Individual rear seats:
The seat cover (1) is secured by a burr fastener and only has to be pushed back carefully.
Detach the seat cover. Take out hex bolt (2). Take off washer (3).
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Press the locking catch (1) in the direction shown by the ar row and raise the seat cushion (2).
Lift out the seat cushion (2) in the direction shown by the curved arrow.
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Separate the cable connector (1) under the seat cushion. Take off the right and left seat cushions.
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Pull off the edge protector (1) in the region of trim cover (2). Pull off trim cover (2) in the direction of the arrow, and remove it.
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Push rubber grommet (1) with loop (2) into holder (3).
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Cars with centre rear armrest:
Fold the centre armrest down and pull off the trim at the burr fastener.
Press the locking catches together as shown by the arrows, and remove the centre armrest.
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Cars with cold-store box:
Remove the right section of the divided luggage compart ment trim.
Take out the locking screw (1).
Push the retaining loop (2) in as shown by the arrow. Pull off the cable plug (3).
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Remove the cold-store box (1) carefully with the aid of a se cond person.
The retaining lugs (2) must be inserted in the cutouts (3).
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Cars with rear-seat head restraints:
Remove the head restraint (1) in the direction shown by the arrow.
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Unscrew and remove hex nuts (1). Unscrew hex bolts (2) for the seat belts.
Tightening torque of hex bolts (2): 48 Nm.
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Fold back the insulating mat (1) at right and left. Unscrew the hex nut (2) at right and left.
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Lift the seat back (1) out of its retainers and pull it forward. Guide the seat belts through the trims (2) and remove the seat back.
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Cars with individual rear seats:
Remove the right and left seat backs.
Unscrew hex nut (1) and take off cushion (2).
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Take the Phillips-head screws (2) out of trim (1).
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Take out Phillips-head screw (1) and remove the trim (2) in the direction shown by the arrow.
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Unscrew and remove hex bolts (1).
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Separate the plug connection (1).
Take out hex bolt (2) and remove washer (3).
Tightening torque for hex bolts (2): 48 Nm.
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Remove the rear seat back (1) as shown by the arrow.
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Remove the rear sill cover strip (1) on the left and right sides of the car.
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Fold back the carpet at the right and left seat bases. Lift out the spreader rivets (1).
Remove the right and left plastic covers (2).
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Cars with burglar alarm:
Unscrew and remove hex nuts (1). Take out hex bolt (2).
Raise cover (3) and pull the cable plug off micro-switch (4).
Remove cover (3).
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Screw the positive lead (1), colour red, to positive terminal (2) and the negative lead (3), colour brown, to the negative terminal (4).
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Insert a 30 Amp fuse (1) into fuse holder (2) and secure the fuse holder (2) inside the seat base.
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Run the connecting cable (1) along the car’s standard wiring harness as shown in the drawing.
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Unscrew and remove hex nuts (1). Take off the wiring harness cover (2).
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Lift out the rubber grommet (1) at the left of the luggage compartment.
Run the additional wiring harness (2) through cutout (3) in rubber grommet (1) and into the luggage compartment.
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Connect the plug (1) on the additional wiring harness with the corresponding plugs (2) on the trailer tow hitch wiring harness (3).
Connect plug (4) of the trailer tow hitch wiring harness (3) to the socket (5) on trailer electrical module (6), and lock by moving in the direction of the arrow,
Install all parts removed according to the instructions in Sec tion 6 by following those instructions in the reverse order.
7. Installing repeater light for trailer flashing turn in dicators
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Carefully lever out the BMW badge (1) at the centre of the steering wheel.
Unscrew and remove self-locking hex nut (2). Take off washer (3).
Mark the position of the steering wheel relative to the steer ing spindle, and pull off the steering wheel.
Do not re-use the self-locking hex nut (2).
Tightening torque for self-locking hex nut (2): 80 Nm.
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Cars with airbag:
For safety reasons, steering wheels with airbag Installed must only be removed by an authorized BMW workshop.
Take out the Phillips-head screws (1). Detach the lower steering column trim (2).
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Pull plug connector (1) out of holder (2), and separate it.
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Unscrew and remove the four steering wheel retaining bolts with special tool I.
Tightening torque of steering wheel retaining bolts: 5 Nm.
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Pull off plug (1) in the direction of the arrow, and take off the airbag unit.
The air bag must only be set down as shown in the drawing, with the plug side upwards.
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Unscrew and remove self-locking hex nut (1). Take off washer (2).
Mark the relative positions of the steering wheel and the steering spindle, and pull off the steering wheel.
Do not re-use the self-locking hex nut (1).
Tightening torque for self-locking hex nut (1): 80 Nm.
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Locking pin (1) must engage in cutout (2).
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Take out the Phillips-head screws (arrows).
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To avoid scratching the instrument cluster (1), cover the steering column (2) with a cloth.
Carefully pull the instrument cluster (1) forwards as far as steering column (2), and swing over.
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Insert the repeater light for the trailer flashing turn indicators (1) into socket (2) on the instrument cluster (3), and turn it through 90° to secure.
Install the instrument cluster (3).
Install the steering wheel and the airbag unit.
8. Changing the flasher relay
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Carefully pull flasher relay (1) out of fuse box (2) and replace it with the flasher relay from the trailer tow hitch electrical component installation kit.
Replace the fuse at socket 22 with a 30 Amp fuse.
9. Making cutout in rear bumper
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The cutout is marked on the rear face of the bumper. Make the necessary cutout for the ball head of the trailer tow hitch in the bumper, using a piercing saw.
Deburr the cut edges.
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Attach clips (1-4) to retain the cover. Attach the rear bumper.
Offer up the cover and lock into position.
10. Installing luggage compartment trim
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Insert ball bead (1) into mounting (2).
Install the spare wheel, jack and side trims.
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The luggage compartment trim is not included in the installation kit.
Attach the adhesive information label (1) to the new luggage compartment trim as illustrated.
Install the luggage compartment trim.
11. Attaching adhesive nose weight labels
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Attach the nose weight information labels to the trim as shown.
Cars with 75 kg nose weight limit:
Attach the adhesive label for 75 kg nose weight in position (1).
Attach the adhesive label for min. 50 kg nose weight in posi tion (2).
Cars with 50 kg nose weight limit:
Attach the adhesive label for 50 kg nose weight in position (2).
12. Functional check
Connect the negative lead to the battery.
Make quite sure that the connections to the plug comply with those in the corresponding socket.
Attach a trailer and check that its lights and flashing turn in dicators operate correctly.
The additional repeater lamp flashes only when a trailer is being towed.