2003 BMW X5 Ac port

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Introduction
The X5 marks BMW’s introduction into the luxury “Sports Activity Vehicle (SAV)” niche seg-
ment of the Sport Utility Vehicle market. While carrying the designation X5, the vehicle is not
based on the 5 Series but it is its own new car-like platform. The X5 is offered with two
engine variants:
• The 4.4 liter M62 TU engine equipped with the A5S 440 Z automatic transmission.
• The 3 liter M54 engine with either the GM 5 automatic or 5 speed manual transmission
The X5 incorporates the following
features:
• Four wheel independent sus-
pension (BMW tradition)
• Full time - all wheel drive
(planetary gear transfer case)
• All road vehicle (ON/OFF road
capabilities)
• High ground clearance
• Unitized body and Chassis
(car like ride and handling)
• Double pivot front suspension
• “Integral Link” rear suspen-
sion with air spring self level-
ing
• X5 specific traction control
system
Two different suspension options are offered (standard and sport) with different springs,
shock absorbers and stabilizers.
The X5 has 180 mm ground clearance, for both suspensions to allow off road travel.
However, the suspension travel is the same as the E39 which allows the X5 to retain a car
like feel when driven every day.
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Body
The design of the X5 originated in California at BMW’s Design Works. The SAV look was
further developed and refined in Munich. Traditional BMW features such as the Kidney
grilles, quad headlights, reverse link rear side window trim and typical rear tail light treat-
ment allow the X5 to assume a BMW identity. Yet the unique side and hood treatments as
well as the large wheel house openings and high ground clearance set the X5 apart as its
own distinctive vehicle.
The design criteria for the X5 was to develop a vehicle with the superb handling and sporty
driving characteristics that are typically BMW, yet produce an all wheel drive vehicle that can
also be used off-road. This was achieved through the use of independent front suspension
and multi-link rear suspension components that are taken from the E38/E39 vehicle design
and expanded by the addition of front drive components.
The entire body shell/frame assembly of the
X5 is reinforced to ensure optimized body
rigidity.
In addition to the cross bracing on the front
suspension/engine carrier, an additional
panel is installed between the bulkhead and
transmission tunnel.
The floor pan of the X5 is reinforced with
additional ribbing and cross braces to
increase the lateral rigidity. A continuous seat
cross brace is connected to the floor pan
and side sill for reinforcement.
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Cross
Brace
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Reinforcement Panel

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Interior/Seats
Two interior seat options (comfort and sport) are available for the X5. The seats are mount-
ed high in the cabin for good visibility and offer 8-way power, memory adjustments with
lumber support. The seat/mirror memory control module and switch assembly is located on
the side of the driver’s seat.
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Front Suspension
The front suspension design is taken from the E38/E39 double pivot system. The compo-
nents are larger in size and made from all steel for the expected harder use that the X5 sus-
pension will receive. This includes the sub-frame which is also larger in size and supported
by two hydraulic mounts for vibration absorbion. The front suspension carrier incorporates
an aluminum stiffening plate that is bolted to the carrier. It adds to the front axle kinematics
by reducing flex in the front suspension. It also provides protection for the oil pan and front
end components when off-road and improves the Cd by providing a smooth surface for air
flow under the vehicle.
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Front Axle Technical Data
TRACK: 1576mm
TOE-IN: 18’ +/-10’
CAMBER: -12’ +/- 20’
S.A.I: 12 Degree’s 48 Feet
CASTER: 7 Degree’s 8 Feet

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Rear Suspension
The rear suspension is the “intragal” multi-link design taken from the E38/E39 vehicles.
Several components AER made from aluminum to erduce the unsprung weight. The X5
with the M62TU engine uses the EHC (air spring) suspension system. The EHC functions
the same as the E39 Sport Wagon with only minor differences to the components and lay-
out of the system. The X5 with the M54 engine will use standard springs in the rear with the
EHC system as an option. The rear struts on the X5 are mounted to the body instead of
the sub-frame.
The rear axle sub-frame is mounted to the body through four bushings (larger than E38) for
increased load and comfort. The rear differential is mounted through three rubber bushings
two in the front and one hydromount in the rear. The wheel bearings are similar to the E39
but incorporate different seals - designed for off-road use.
New special tools are available for adjusting the rear suspension due to the limited space.
Rear Axle Technical Data
Track: 1576mm
Toe In: 18 Feet
Camber 1 Degree 50 Feet

Air Springs
The air spring is made from a flexible rubber material. It
forms an air tight cavity which provides the calculated spring
rate required for the sport wagon.
As the spring compresses downward the bottom edge of
the rubber material rolls along the vertical surface of the
base mount cylinder.
Air is added or removed from the air spring through its top
port. The top port of each spring is connected to a reser-
voir and the air supply pipes. The reservoirs are required to
hold additional air due to the compact design of the springs.
Rear Axle Level Sensors
Hall effect sensors are mounted on the left
and right sides of the rear suspension for ride
height detection. They are pivoted by a cou-
pling rod through the rear axle swing arms.
The hall sensors produce a varying voltage
input to the control module as the suspension
height changes.
If the vehicle is equipped with Xenon head-
lights the right side sensor contains an addi-
tional sensor for the automatic headlight level
adjustment system.
Warning Display
If the system is faulted and off-line or set in the transport mode, the following is displayed:
High Cluster: A message is posted in the high cluster matrix display.
E39 Features 07
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EHC System Operation
A fully functional EHC system is controlled by one of three different modes of operation.
The operation mode is selected by the control module based on current conditions provid-
ed by the monitored input signals. The main modes of operation are:
• Pre-Run/Post-Run Mode
 Normal Mode
 Tailgate Mode
Two special operating modes are also included in the control module programming.
 New/replacement mode(pre ZCS encoded). This mode provides basic operation.
 Transport Mode - Transport mode is set at the factory and raises the vehicle 30mm to
prevent vehicle damage during transportation. It must be deactivated with the DIS/
MoDiC prior to customer delivery.
Pre-Run/Post-Run Mode
The Pre-Run mode is activated when the vehicle is parked and the control module is in the
sleep mode. Opening a door or the tailgate initiates a system wake up and the control mod-
ule comes on-line.
The control module performs a self-check of the control electronics and sensors. If no fault
is found, the system will check the ride height and institute a rapid regulation if the height
varies by more than 40mm.

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DIS/Modic Service Funnction Program
The Service Functions program of the DIS/MoDiC provides the Transport Mode activa-
tion/deactivation and Ride Height Offset functions (see next page).
Once the transport mode has been released, or if the system requires left to right side
height adjustment, the ride height "OFFSET" must be carried out to ensure that the vehi-
cles suspension has a base ride height level starting point.
The "HEIGHT OFFSET" is adjusted using the DIS or MoDiC. The procedure is as follows:
• Place the vehicle on a level surface unloaded.
• Access the Height Offset program in the service function menu.
• Measure the base ride height from the lower edge of the wheel housing to the center of
the wheel hub.
• Check measured height against the specifications listed
• Use the DIS/MoDiC to correct the ride height if the value differs from the listed specifi-
cation.