My New Project: 2002 X5 4.6is

[BimmerM3inGA]

I spent some time this weekend getting to know the X5 and sorting some of the easier issues.

The brake fluid was looking pretty nasty, so that got flushed with fresh fluid. I don't know how I didn't know this, but I was unaware that the 4.6is has two-piston front brake calipers and vented rear rotors. Just like an M car. Pretty cool!

While the wheels were off, I also gave the suspension a once-over. Everything looks pretty good except the rear upper links. The rubber boots for the ball joints are pretty rotten. I added those to my list and will replace them when I lower the suspension with the new springs. It'll need an alignment anyway and it makes sense to take care of it all at once.

Also new on the list is an outer CV boot on the passenger side. The inside of the wheel was covered in grease due to a rip in the boot. So I've parked the car until the new boot gets installed. The CV joints themselves seem fine - no popping or clicking, so I'll just repack it with grease and install a new boot. But I don't want to risk causing damage by continuing to drive it.

I've replaced entire axles before, but haven't ever done just the boot. I found a couple of DIY's and it doesn't look too difficult. It certainly looks like a lot less work than changing the axle. It's definitely a hell of a lot less money! Hopefully it will go smoothly.

Now for the big breakthrough: I believe I have solved the airbag warning light problem. In hindsight, I should have figured it out quicker than I did. But in my defense, the error descriptions in DIS and INPA can be quite cryptic. They each gave a slightly different description of the fault, but it basically said "Side Airbag, rear right. Coding data does not match equipment. Currently present".

There were a few service receipts that came with the car. One was for a recent replacement of the right rear window regulator. Easy, I thought.
My initial interpretation of this fault was that when the regulator was replaced, somebody switched on the ignition to test the window but had the airbag unplugged. I'll just reset the code and be done with it. When I did, the SRS light flashed until I turned off the ignition. Weird. But the light stayed off when I started the engine. Then came back on. OK, something else is going on here.

I removed the door panel to check the airbag connection. I unplugged it, made sure it was properly connected and reset the fault codes again. Same thing as last time: Light flashed until ignition was turned off. Then came back on when the engine was started.

Then I noticed this label and it clicked.


I remembered either reading or being told that when a dealer disables the rear airbags in a BMW so equipped, they not only disable them by recoding the control module, they also physically disconnect them. That seemed illogical to me, though. On a 2002 X5 rear airbags were a $500 option. Why would someone pay extra for rear airbags and then have them disabled?

What did seem logical though, was that the error code was telling me that the physical configuration did not match the electronic configuration. In other words, the module was detecting a right rear airbag as being present, but there shouldn't be one.

It's easy enough to test that theory: Unplug it, clear the code, and see what happens. What happened was that the SRS light did not flash when I cleared the code and been staying off. I've put about a half dozen drive cycles on it since clearing the code, and so far the light is staying off.

It's funny how obvious a solution is once you've figured it out!

Lastly, I had found an SMG steering wheel on eBay from a 2004 M3. It was delivered today and looks okay. It's pretty dirty, though. I'll clean it up and see how it looks then. Even though I'm not ready to do the shift paddle mod yet, I'll probably go ahead an install it since I like it better than the wheel in the car now. Then half the work will already be done when I'm ready to complete the mod.

[Riggodeaux]

BimmerM3, your clear explanation of your airbag troubleshoot shows why we appreciate your contributions here! Thanks and keep us up on your adventure!

[BimmerM3inGA]

Here's a quick update on this project:

I sent the cluster to VDO Repair for diagnosis. I've spoken to the tech several times about it since, and as of now (3 weeks later) they still have it. The basic problem is that someone attempted a repair in the past by swapping the main control board and transferring the primary CPU to the new board. But in doing so, damaged the chip. Also, the replacement control board is lacking the connector for the variable redline - which is why that feature doesn't work.

The plan now is to replace the CPU chip with a new one, code the VIN and set the mileage to "0". He didn't have the software tools on hand to properly code the chip, so he ordered what he needs and that's the reason why it's taking so long.

Since I wasn't sure what to expect when I sent in my cluster, I thought it might be a good idea to have a backup plan. I found a really nice used 4.6is cluster on eBay, bought it, and sent it to VDO Repair along with my original cluster. The idea being that if mine can't repaired, I could recode the new one and use that instead. But since my original CPU is damaged, that plan won't get me going any sooner since we still need the programming tools.

Maybe I would have been better off just buying a new cluster from BMW?

Since the X5 isn’t going anywhere for a while, I decided to get it caught up on some urgent and remedial maintenance.

Urgent Maintenance #1:
One of the outer CV boots was torn, so I replaced that. I removed and cleaned the CV joint, and since it’s still in great condition, I only replaced the boot. Having plenty of time, I did it the hard way by removing the entire steering knuckle. This is a lot of extra work, but it does greatly improve access to the CV joint. It also made it possible to completely clean off all the old grease that was flung out of the torn boot.

Urgent Maintenance #2:
Oil was leaking from the Bank 1 valve cover and Bank 2 upper timing cover gaskets. I debating going ahead and having the valve covers powder coated while I had it apart, but decided to wait on that until the next time I have to take it apart. It was also due for an oil change, and I wanted to check on the condition of the timing chain guides. So after draining the oil, I removed the oil pan to check for any broken pieces of the chain guides. Thankfully, there was no evidence of deteriorating guides. With the upper timing covers off, I could see about half of the guides and also visually inspected them. Again, no evidence of failures (yet). So I buttoned it back up with new upper timing cover and valve cover gaskets on both banks, new VANOS solenoid gaskets, a new thermostat, and a new A/C compressor belt.

Remedial Maintenance #1:
With that done, and having had to drain most of the coolant anyway, I figured it was a good time to flush the coolant. The old stuff has been drained out and I filled it with distilled water for the time being until I can run the engine enough to thoroughly circulate the coolant and flush out all the old coolant.

Remedial Maintenance #2:
I wasn’t planning to change the drivetrain fluids yet (diffs, transfer case) but the big aluminum skid plate has to be removed to drain and fill the front diff. It was already off to get to the oil pan, so I figured what the hell, and took care of that too.

I’ve also thoroughly cleaned everything that was removed, or that I could get access to with other bits removed.

So as of now, it’s all put back together and ready to go except for finishing bleeding the coolant and the instrument cluster repair.

[Ricky Bobby]

^Good news on the "remedial maintenance" while waiting for cluster to be repaired. Time will tell if VDO Repair is going to be a cheaper route than going to BMW. If I recall correctly a new 4.6/4.8 cluster plus programming from BMW runs about a grand.

If you make out cheaper than that it would be a good save. However, obviously if you needed the car right away and couldnt take any downtime, you would have to pony up the cash to BMW.

[BimmerM3inGA]

Yeah, it's a good thing that I'm able to let the car sit for nearly a month while I wait for the cluster repair. It's frustrating, but at least I'm not stranded or significantly inconvenienced by it.

I have a feeling that it will end up being a wash cost-wise by the time all the checks have cleared the banks. I'm adding to the expense by also having the replacement cluster "rebuilt" along with the original in case I need it. If I don't need it, I can try to sell it and recover some of the money spent.

How much would you reckon a cluster from a 2003 4.6is with freshly rebuilt LCD panels and 0 miles would fetch?

[Ricky Bobby]

Hmmm I'd probably say 300 ? Thats a guess, since I know they have to be coded to the VIN otherwise they throw a tamper dot.

I'm looking at it from the value it would have to swap onto another vehicle, say a 3.0 or a 4.4, etc - For me it was more cost efficient to add silver rings (or gauge faces too if you prefer) and just repair the cluster for $120 and call it a day.

[BimmerM3inGA]

The 4.6 cluster is unique, and I'm not sure if it'll work in a regular 4.4 or 3.0. Which may make it more or less valuable. It also already has matte silver gauge rings - I think that was standard for the 4.6 because every one that I've seen has them.

I can have the cluster coded to the proper VIN, and with the mileage reset to 0, it won't trigger the tamper dot - the car will think it's a new cluster.

Anyway, I hope I can get more than $300. I already have more than that in it! I would think having the mileage zeroed out and the correct VIN has to be worth something?

[Ricky Bobby]

All based on what the market is willing to pay, I have zero experience in that. However I will say the guy parting the 4.6 in the classifieds did sell the cluster extremely quickly, so maybe pm him to ask what he sold it for (Deansbimmer)

[BimmerM3inGA]

Nice!! And it really is just bolt on?

[o. l. t.]

Beautiful truck. I had similar issues with my. Passenger door connector in 2011 when I bought my x5 and did a thread on it. They tend to corrode inside the pins. Love the wheels, my 4.4 wheels aren't cutting it anymore. Time for me to find some like that.