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Steps
You may want to disconnect the battery – I did not
Inside the X5
Disassembly
1. Remove spare tire
2. Remove the trim for the retractable cargo floor
3. Remove the plastic trays around the spare tire
4. Remove the 6 x 16mm nuts on each side (3 on each side)
5. Disconnected the Park Distance Control connector on the left hand side of the cargo area
6. Push the PDC connector through the hole in the rear
7. Remove 2 x 13mm nuts toward rear of dome underneath the spare tire
8. Remove 2 x 13mm bolts toward front of dome underneath spare tire
9. Push the dome (self leveling suspension) out of the way
10. Remove 3 screws to access the battery
11. Remove 4 screws that hold the plastic tray where the tuner is and or PDC module
Outside the X5
Disassembly
12. Remove the exhaust ring trim – normally would not be on a 02 4.6is…I added these
13. Remove the lower 8mm bolt from inside both rear fender wells
14. Remove 2 T55 bolts that hold the bumper in place
15. Remove the bumper – remember to disconnect the 4 tabs underneath where the bumper is mounted to the lower part of the vehicle
16. Remove bumper shocks
17. Remove the front and rear exhaust hangers at rear of body (both sides) (4 X 13mm nuts on each side) Also there are 2 additional 13mm nuts to hold the ground strap in place
18. Remove the heat shields from each side (2 x 10 bolts and 2 x 10 washer nuts on each side)
19. Remove 2 x 13mm bolts that hold bumper shock frame to rear of body
20. Remove 8 x T45 bolts from bumper shock frame
21. Remove bumper shock frame
Assembly
22. Run the wire harness through the opening in the middle of the rear of vehicle
23. From the cargo area run the harness to the rear left and connect it to the empty connector in the spare tire well – there is a cap on this that must be removed
24. From the cargo area where the battery is remove the large L shaped plastic tray that holds the tuner module and PDC module and insert the electronic control module for the hitch wiring.
25. Plug in the connector to the electronic control module
26. Mount new hitch support bracket in the pentagon shaped opening (1 on each side)
27. I also re-installed 5 of the T45 bolts back into the holes – this is probably not necessary but I did it anyway.
28. From the bottom of the X5 where the heat shields were, install 1 x 16mm x 85mm bolt and washer in to the rear (closest to rear of vehicle) hole into the hitch support bracket (1 on each side) *** Finger tighten
29. From the bottom of the X5 where the heat shields were, install 1 x 16mm x 30mm bolt and washer in to the front (closest to front of vehicle) hole into the hitch support bracket (1 on each side) *** Finger tighten
30. On the hitch assembly insert 2 x 16mm x 40mm bolts in each mounting location and take a hammer and bend down the tabs that hold the bolts in place (2 on each side)
31. The hitch assembly is very heavy, but one person can do this…lift it into place (it is obvious where it goes) and from the lower portion of the bumper support finger tighten 1 washer nut on each side..I hope you ate your Wheaties in the morning.
32. From inside the vehicle, tighten the top bumper mount with 1 washer nut on each side.
33. Once all 4 of these nuts are in position, you can tighten all 4 down to 55 lbs using a good torque wrench.
34. Mount the wire harness and plug assembly to the hitch assembly – use the 2 x 10mm bolts and 4 screws included in the kit
35. Find both bumper support brackets and install 2 x 16mm x 120mm bolts into each one (total of 2 brackets and 4 bolts) hammer the tabs down to hold the bolts in place
36. Mount the bumper support brackets to the hitch assembly with the longer part of the tube facing down
37. From inside the vehicle finger tighten 2 x 16mm washer nuts – You will not tighten these down until you mount the bumper
38. Tighten the 2 x 16mm bolts that you installed (bumper earlier from the bottom of the rear of the vehicle. (2 on each side @ 55 lbs)
39. At this time you can re-install the heat shields and the muffler supports – remember to install the ground strap on each muffler hanger
40. Re-install the bumper on the X5 carefully and align the 2 tabs on the side where the bumper meets the fender wells – don’t forget the PDC wiring harness
41. Re-install the 8mm bolt from inside the fender well (1 on each side)
42. Re-install the 2 x T55 bolts back into the bumper and tighten to 55 lbs
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pepatrick
2002 X5 4.6is
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