Original BMW Accessories. Installation Instructions

Original BMW Accessories. Installation Instructions. LED Headlight Retrofit BMW 1 Series 5-door (F20) BMW 1 Series 3-door (F21) BMW 3 Series Saloon (F30 LCI) BMW 3 Series Touring (F31 LCI) Installation instructions applicable only to F2x cars build after 03/2015 and F3x cars built after 07/2015.

Retrofit kit number 61 12 2 410 239 LED headlight retrofit wiring harness

Installation time The installation time is approx. 7.00 hours. This may vary depending on the condition of the vehicle and its equipment. The installation time shown does not include any time spent on programming/coding. The calculation of the total costs for the programming time must be factored into the calculation of retrofitting costs (no invoicing via warranty).

Important information These installation instructions are primarily designed for use within the BMW dealership organisation and by au- thorised BMW service companies. These installation instructions are intended for use by qualified specialist staff trained on BMW vehicles with the relevant expert knowledge. All work must be completed using the latest BMW repair manuals, wiring diagrams, servicing manuals and work instructions, in a logical order, using the prescribed tools (special tools) and observing current health and safety regulations.

If you experience installation or function problems, restrict troubleshooting to approx. 0.5 hours for mechanical work and 1.0 hour for electrical work. To avoid unnecessary extra work and/or costs, send an inquiry straight away to the technical parts support team via the Aftersales Assistance Portal (ASAP). Quote the following information: – Chassis number, – Retrofit kit part number, – A detailed description of the problem, – any work already carried out. Do not archive the hard copy of these installation instructions since daily updates are provided via ASAP.

Pictograms Denotes instructions that draw your attention to dangers. ! Denotes instructions that draw your attention to special features.

Denotes the end of the instruction or other text.

© BMW AG, Munich 01 29 2 420 333 11/2016 (Z/Z) 2.2 1/21 Installation information Ensure that the cables and/or lines are not kinked or damaged as you install them in the car. Costs arising from this will not be reimbursed by BMW AG. Additional cables/wires that are installed must be secured with cable ties. If the specified PIN chambers are occupied, bridges, double crimps, or twin-lead terminals must be used. All pictures show LHD cars; proceed accordingly on RHD cars. All illustrations show F3x cars; proceed similarly on F2x cars. After the installation work, the retrofit must be programmed / coded via the – Conversions – path.

Ordering instructions The LED headlight retrofit is not a retrofit kit. All the parts required for the LED headlight retrofit must be ordered separately for the appropriate car version and year of manufacture (for part numbers and instructions, see EPC).

Special tools required Details of the special tools required can be found in the relevant ISTA repair manual.

Section Page 1. Parts list for retrofit kit ...... 4

2. Preparatory work ...... 5

3. Retrofit wiring harness connection diagram ...... 6

4. Connection diagramfor level sensors ...... 7

5. Installation and cabling diagram for retrofit wiring harness ...... 8

6. Installation and cabling diagram for level sensors ...... 9

7. Retrofitting the LED headlight ...... 10

8. Retrofitting the level sensors ...... 14

9. Concluding work and coding ...... 18

10. Retrofit wiring harness wiring diagram ...... 19

11. Level sensors wiring diagram ...... 21

A B C D E

F G H I J K L M N

O P Q R S T U V W

F30 0484 Z

Legend A Retrofit wiring harness B Right LED headlight C Left LED headlight D LED module (4 x) (part of the LED module set) E LED flasher module (2 x, for F3x cars only) F LED module (2 x, for F3x cars only) (part of the LED module set) G Front electronic light control unit (2 x) H Light operating unit I Rear level sensor retrofit wiring harness (part of retrofit wiring harness A) J Front level sensor retrofit wiring harness (part of retrofit wiring harness A) K Level sensor (2 x) L Front level sensor holder M Oval-head screw (24 x for F3x, 14 x for F2x) N Control rod O Hexagon nut (3 x) P Hexagon screw (2 x) Q Insert nut (2 x) R Rear level sensor holder S Deflection rod T Cable tie U Mini 15 A fuse (2 x) V ISA screw (4x) W SW 3+3-pin socket housing (for F2x only)

ISTA No. Disconnect the negative terminal of the battery 61 20 900

The following components must be removed first of all Front bumper trim 51 11 156 Right headlight (no longer required) 63 12 009 Left headlight (no longer required) 63 12 003 Left and right engine compartment cover 51 13 ... Pedal trim 51 45 184 Bottom right dashboard trim 51 45 195 Centre console 51 16 165 Right A-pillar footwell side trim 51 43 075 Front right (interior) door sill cover strip 51 47 000 Bottom right B-pillar trim 51 43 150 Rear right (interior) door sill cover strip 51 47 030 Luggage compartment floor trim 51 47 101 Luggage compartment wheel arch trim, right 51 47 161 Rear fuse box (release only) 61 14 010 Right rear seat backrest side section 52 26 008 Front fuse box (release only) 61 14 005 Camber control arm cover, left (nuts must be replaced, for part numbers and identification, 33 32 188 see EPC) Underbody shield on the left 51 71 017 Left front and rear wheel 36 10 300 Rear left wheel arch cover 51 71 041 Front left wheel arch cover (front section) 51 71 038 Front left wheel arch cover (rear section) 51 71 039 Left tank cover 51 75 ...

Item Designation Signal Cable colour/ Connection location in the car Abbreviation/ Cross-section Slot A Retrofit wiring harness ------A1 Socket contact B-CAN_H OR/GE To right headlight E5/B E5*1B 0.35 mm² PIN 9 A2 Socket contact B-CAN_L OR/GN To right headlight E5/B E5*1B 0.35 mm² PIN 10 A3 Socket contact Terminal 30 RT/SW To right headlight E5/B E5*1B 2.5 mm² PIN 3 A4 Socket contact B-CAN_H OR/GE To left headlight E86/C E86*1B 0.35 mm² PIN 9 A5 Socket contact B-CAN_L OR/GN To left headlight E86/C E86*1B 0.35 mm² PIN 10 A6 Socket contact Terminal 30 RT/SW To left headlight E86/C E86*1B 2.5 mm² PIN 3 A7 Double flat spring contact 30_F40_vBF RT/SW To front fuse box Z7 Z7*10B 2.5 mm² PIN 2 A8 Socket contact B-CAN_H OR/GE To FEM A173 A173*2B 0.35 mm² PIN 21 A9 Socket contact B-CAN_L OR/GN To FEM A173 A173*2B 0.35 mm² PIN 20 A10 Socket contact B-CAN_H OR/GE To FEM A173 A173*8B 0.35 mm² PIN 50 A11 Socket contact B-CAN_L OR/GN To FEM A173 A173*8B 0.35 mm² PIN 49 A12 Double flat spring contact 30_F100_HR RT/SW To rear right fuse box Z2 Z2*5B 2.5 mm² PIN 5

Item Designation Signal Cable colour/ Connection location in the car Abbreviation/ Cross-section Slot I Rear level sensor retrofit wiring ------harness I1 BR 6-pin socket housing ------To rear left level sensor B11*1B I2 Socket contact LWR_H_ SW/WS To ICM control unit A78 A78*1B GROUND 0.35 mm² PIN 9 I3 Socket contact LWR_H_ Ein SW/GN To ICM control unit A78 A78*1B 0.35 mm² PIN 8 I4 Socket contact LWR_H+ SW/GR To ICM control unit A78 A78*1B 0.35 mm² PIN 36

J Front level sensor retrofit wiring ------harness J1 BR 6-pin socket housing ------To front left level sensor B39*1B J2 Socket contact LWR_V_ GR/WS To ICM control unit A78 A78*1B GROUND 0.35 mm² PIN 27 J3 Socket contact LWR_V_ Ein GR/GN To ICM control unit A78 A78*1B 0.35 mm² PIN 26 J4 Socket contact LWR_V+ GR/BR To ICM control unit A78 A78*1B 0.35 mm² PIN 35

Disconnect branches I2-I4 and J2-J4 from connector (1). Connector housing (1) is no longer required.

A Retrofit wiring harness B Left LED headlight C Right LED headlight

1 Rear fuse box Z2 2 FEM control unit A173 3 Rubber grommet 4 Front fuse box Z7

I Rear level sensor retrofit wiring harness J Front level sensor retrofit wiring harness K Level sensors

1 Rubber grommet 2 ICM control unit A78

Note the tightening torque of oval-headed screws M: 1.65 Nm. F3x cars only Connect LED indicator module E to headlights B and C and secure with oval-headed screws M. All cars Connect LED modules D to headlights B and C and secure with oval-headed screws M.

F3x cars only Connect LED modules D to headlights B and C and secure with oval-headed screws M. All cars Plug front light electronic unit G into headlights B and C and secure with oval-headed screws M. Install headlights B and C.

Route the retrofit wiring harness starting from ! the passenger footwell. Ensure that, when you drill, you do not damage any cables in the car. Move the passenger side footwell mat to one side. Using a 6 mm diameter drill bit, drill a hole through the cable grommet (1). Route branches A1-A3 through the drill hole into the engine compartment.

Route branches A1-A3 to plug E5*1B on the headlight on the right and secure using cable ties T to the standard wiring harness.

Disconnect the standard cables and connect branches A1-A3 as follows to plug E5*1B: – Disconnect the standard cable from PIN 9 and connect branch A1, OR/GE cable – Disconnect the standard cable from PIN 10 and connect branch A2, OR/GN cable – Disconnect the standard cable from PIN 3 and connect branch A3, RT/SW cable Insulate and tie back the cables that have been dis- connected (no longer required).

Ensure that, when you drill, you do not damage ! any cables in the car. Place the driver's side footwell mat to one side. Using a 6 mm diameter drill bit, drill a hole (2) through at the cable grommet (1).

Route branches A4-A6 to the driver's footwell. Route branches A4-A6 through the rubber grommet (1) to plug E86*1B on the headlight on the left and secure using cable ties T to the standard wiring harness.

Disconnect the standard cables and connect branches A4-A6 as follows to plug E86*1B: – Disconnect the standard cable from PIN 9 and connect branch A4, OR/GE cable – Disconnect the standard cable from PIN 10 and connect branch A5, OR/GN cable – Disconnect the standard cable from PIN 3 and connect branch A6, RT/SW cable Insulate and tie back the cables that have been dis- connected (no longer required).

If socket housing Z7*10B is not installed, use 3+3 pin SW socket housing W. Route branch A7 to the installation point for front fuse box Z7. Connect branch A7 to PIN 2 of plug Z7*10B, SW 3+3-pin socket housing.

Insert fuse U into slot F40 of fuse box Z7.

If the PIN compartments on the control unit FEM A173 should be occupied, connect branches A8-A11 with mini-connectors (not part of the retrofit kit). Route branches A8-A11 to FEM control unit A173 and connect as follows: – branch A8, OR/GE cable, to plug A173*2B, SW 42-pin socket housing, PIN 21 – branch A9, OR/GN cable, to plug A173*2B, SW 42-pin socket housing, PIN 20 – branch A10, OR/GE cable, to plug A173*8B, SW 54-pin socket housing, PIN 50 – branch A11, OR/GN cable, to plug A173*8B, SW 54-pin socket housing, PIN 49

Reconnect the standard cables on plug A173*4B, SW 54-pin socket housing, of FEM control unit A173 as follows: – Disconnect the GE/SW cable from PIN 37 and connect to PIN 54 – Disconnect the GE/RT cable from PIN 49 and connect to PIN 53

Route branch A12 to the installation point for rear fuse box Z2. Connect branch A12 to PIN 5 of plug A173*2B, GE 6+6-pin socket housing.

Insert fuse U into slot F100 of fuse box Z2.

Insert insert nut Q into the cut-out (1) on the left rear axle support (2).

Ensure that the anti-twist lock (1) on level sensor holder R engages into the existing drill hole. Screw level sensor K onto level sensor holder R using ISA screws V. Screw holder R into place using hexagon screw P.

Ensure that the anti-twist lock (1) on deflection rod holder S engages into the existing drill hole. Screw deflection rod S using hexagon nut O onto level sensor K. Screw deflection rod holder S using hexagon nut O to the left rear axle support (1).

Connect branch I1 of retrofit wiring harness I to level sensor K. Route retrofit wiring harness I to the installation point of the front left wheel arch rubber grommet and secure with cable ties T.

Insert insert nut Q into the cut-out (1) on the left front axle support (2).

Ensure that the anti-twist lock (1) on level sensor holder L engages into the existing drill hole. Screw level sensor K onto level sensor holder L using ISA screws V. Screw holder L into place using hexagon screw P.

Place the clip (2) from control rod N around the cut- out on the wishbone (1) and lock. Screw control rod N using hexagon nut O onto level sensor K.

Connect branch J1 of retrofit wiring harness J to level sensor K. Route retrofit wiring harness J to the installation point of the front left wheel arch rubber grommet and secure with cable ties T.

Route retrofit wiring harnesses I and J through the rubber grommet (1) and secure with cable ties T.

Route retrofit wiring harnesses I and J through the rubber grommet (1) into the interior of the car and to the installation point of the ICM control unit.

Connect branches I2-I4 and branches J2-J4 as follows to plug A78*1B, SW 54-pin socket housing, of ICM control unit A78: – Branch I2, SW/WS cable, to PIN 9 – Branch I3, SW/GN cable, to PIN 8 – Branch I4, SW/GR cable, to PIN 36 – Branch J2, GR/WS cable, to PIN 27 – Branch J3, GR/GN cable, to PIN 26 – Branch J4, GR/BR cable, to PIN 35

The retrofit system requires programming/coding. – Connect the battery – Connect the battery charger to the car – Connect the car to the ISTA workshop system – Open the ISTA/P car programming facility – If using ISTA/P, please note the instructions provided in the ISTA/P application documentation – Select the "LED Headlight" retrofit via the - Conversions - path and work through the created action plan – If necessary, carry out a car test using the ISTA system and note or work through any entered error memory – Conduct a function test – Adjust the headlights as described in ISTA 63 10 004 – Re-assemble the car

Legend A1* Socket contact, to plug E5*1B, SW 12-pin socket housing, on right headlight B* A2* Socket contact, to plug E5*1B, SW 12-pin socket housing, on right headlight B* A3* Socket contact, to plug E5*1B, SW 12-pin socket housing, on right headlight B* A4* Socket contact, to plug E86*1B, SW 12-pin socket housing, on left headlight C* A5* Socket contact, to plug E86*1B, SW 12-pin socket housing, on left headlight C* A6* Socket contact, to plug E86*1B, SW 12-pin socket housing, on left headlight C* A7* Double flat spring contact, to plug Z7*10B, SW 3+3-pin socket housing, on front fuse box Z7 A8* Socket contact, to plug A173*2B, SW 42-pin socket housing, on FEM control unit A173 A9* Socket contact, to plug A173*2B, SW 42-pin socket housing, on FEM control unit A173 A10* Socket contact, to plug A173*8B, SW 54-pin socket housing, on FEM control unit A173 A11* Socket contact, to plug A173*8B, SW 54-pin socket housing, on FEM control unit A173 A12* Double flat spring contact, to plug Z2*5B, GE 6+6-pin socket housing, on rear fuse box Z2

B* Right headlight E86 C* Left headlight E5 A173 FEM control unit E5 Right headlight E86 Left headlight Z2 Rear fuse box Z7 Front fuse box

A173*2B SW 42-pin socket housing on FEM A173 A173*8B SW 54-pin socket housing on FEM A173 E5*1B SW 12-pin socket housing on right headlight E5 E86*1B SW 12-pin socket housing on left headlight E86 Z2*5B GE 6+6-pin socket housing on rear fuse box Z2 Z7*10B SW 3+3-pin socket housing on front fuse box Z7

All of the designations marked with * apply only to these installation instructions or this wiring diagram.

Cable colours BL Blue GR Grey RT Red BO Bordeaux L-GN Light green SW Black BR Brown NT Natural TR Transparent GE Yellow OR Orange VI Violet GN Green RO Pink WS White

Legend I1* BR 6-pin socket housing, plug B11*1B, to level sensor K I2* Socket contact, to plug A78*1B, SW 54-pin socket housing, on ICM control unit A78 I3* Socket contact, to plug A78*1B, SW 54-pin socket housing, on ICM control unit A78 I4* Socket contact, to plug A78*1B, SW 54-pin socket housing, on ICM control unit A78

J1* BR 6-pin socket housing, plug B39*1B, to level sensor K J2* Socket contact, to plug A78*1B, SW 54-pin socket housing, on ICM control unit A78 J3* Socket contact, to plug A78*1B, SW 54-pin socket housing, on ICM control unit A78 J4* Socket contact, to plug A78*1B, SW 54-pin socket housing, on ICM control unit A78

K* Level sensors

A78 ICM control unit B11 Rear left level sensor B39 Front left level sensor

A78*1B SW 54-pin socket housing, to ICM control unit B11*1B BR 6-pin socket housing to rear left level sensor B39*1B BR 6-pin socket housing to front left level sensor

Cable colours BL Blue GR Grey RT Red BO Bordeaux L-GN Light green SW Black BR Brown NT Natural TR Transparent GE Yellow OR Orange VI Violet GN Green RO Pink WS White