Parts and Accessories

Installation Instructions

F 46 0103 EVA

Xenon Light with Automatic Headlight Adjustment Control

BMW 3 Series (E 46)

The installation time is approx. 5 hours, but this may vary depending on the condition of the car and the
equipment in it.
Retrofit kit No. 63 12 9 416 523
63 12 9 416 439
63 12 0 141 698
63 12 0 141 622
63 12 0 030 027
63 12 0 030 025
63 12 0 009 780
63 12 0 004 350
63 12 0 146 003
63 12 0 146 001

Retrofit kit No. 63 12 9 416 523 (others see cover sheet)

Installation Instructions No. 01 29 9 416 445 Issue date: 1.2002
Contents

Section Page

Important information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1. Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. Installation and cabling diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. Xenon wiring harness connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. To install the front right level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5. To install the rear right level sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6. To install the xenon headlights and connect the bi-xenon light adapter cable . . . . . . . . . . . . . . . . . 9
7. To install the xenon wiring harness and replace the light module. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8. To affix the warning sticker and assemble the car . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
9. Coding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10. Function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
11. To adjust the headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
12. Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Retrofit kit No. 63 12 9 416 523 (others see cover sheet) EN/2
Installation Instructions No. 01 29 9 416 445 Issue date: 1.2002
Important information

The retrofit kit is only for use within the dealership organisation.

This retrofit system may only be operated in ECE countries in conjunction with a headlight cleaning
system."

Target group
The target group for these installation instructions is specialist personnel trained on BMW cars with specialist
knowledge of vehicle electrical systems.
All servicing, repair and installation work on BMW cars is completed at your own risk.
All work must be completed using the latest BMW repair manuals, servicing manuals, diagnostics
handbooks, circuit diagrams and work instructions in a rational order using the prescribed tools (special tools)
and observing current health and safety regulations.

Safety instructions
Before installation, please note the following:

All tightening torque values are to be taken from the current repair manuals and must be observed.

Ensure that cables and lines are not kinked or damaged as you install them and that they do not interfere with
the freedom of movement of other vehicle components.
If the specified PINs and chambers are occupied, bridges, double crimps or twin-lead terminals must be
used.

Special tools required

Crimping pliers
DIS or MoDiC

Retrofit kit No. 63 12 9 416 523 (others see cover sheet) EN/3
Installation Instructions No. 01 29 9 416 445 Issue date: 1.2002
1. Preparations

TIS instruction No.

Print out error memory
Disconnect the battery

The following components must be removed first of all:

On 4-cylinder models up to 9/2001: Battery and battery holder
Wheel on the front right
Wheel arch trim on the front right
Washer reservoir
Glove compartment
Trim below glove compartment
Door sill strip on right
A pillar trim at the bottom right
B pillar trim at the bottom right
Pedals and steering column cover
Oddments box on driver's side
Rear seat bench and backrest
Boot cover

Only in RHD cars:

Accelerator pedal module

Retrofit kit No. 63 12 9 416 523 (others see cover sheet) EN/4
Installation Instructions No. 01 29 9 416 445 Issue date: 1.2002
2. Installation and cabling diagram

4
2

046 0926 V

Legend

1 Level sensor front right

2 Level sensor rear right
3 Light module (LHD cars)
4 Light module (RHD cars)

Retrofit kit No. 63 12 9 416 523 (others see cover sheet) EN/5
Installation Instructions No. 01 29 9 416 445 Issue date: 1.2002
3. Xenon wiring harness connection diagram

A3 A4
A2 A5
A1 A6

C1 B1
C C2 B2 B
C3 B3

D
F 46 0104 EVA

Item Description Signal Cable colour Connection location in the car Abbreviation / Slot
A1 Blade terminal contact --- GR/WS Light module on driver's side X12/19
A2 Blade terminal contact --- GR/GN Light module on driver's side X12/22
A3 Blade terminal contact --- GR/BR Light module on driver's side X12/23
A4 Blade terminal contact --- SW/GR Light module on driver's side X12/26
A5 Blade terminal contact --- SW/GN Light module on driver's side X12/14
A6 Blade terminal contact --- SW/WS Light module on driver's side X12/46
B 6-pin socket casing --- --- Level sensor front right X1451
B1 Blade terminal contact --- GR/WS Level sensor front right X1451/1
B2 Blade terminal contact --- GR/GN Level sensor front right X1451/4
B3 Blade terminal contact --- GR/BR Level sensor front right X1451/5
C 6-pin socket casing --- --- Level sensor rear right X13251
C1 Blade terminal contact --- SW/WS Level sensor rear right X13251/1
C2 Blade terminal contact --- SW/GN Level sensor rear right X13251/4
C3 Blade terminal contact --- SW/GR Level sensor rear right X13251/5
D Cable grommet --- --- Cable passage in the boot ---

Retrofit kit No. 63 12 9 416 523 (others see cover sheet) EN/6
Installation Instructions No. 01 29 9 416 445 Issue date: 1.2002
4. To install the front right level sensor

Secure the holder for the level sensor to the holes

1 (1) on the frame.
Secure the angle joint to the hole (2) in the rocker
arm."

F 46 0094 EVA
0

Secure the holder (1) to the holes on the frame using a

0

1 self-locking nut M6 (2).

Secure the level sensor (3) to the holder (1) using two pan
head screws M5x10 (4) (check the coding on the level
sensor, see magnified view).
2
3
4

046 0927 V
0

Secure the angle joint (1) to the hole (2) in the rocker arm
0

using a self-locking nut M8. Connect the angle joint (1)

and the lever on the level sensor and secure them using
a self-locking nut M6 (3).

1 3

2
046 0928 V
0

Retrofit kit No. 63 12 9 416 523 (others see cover sheet) EN/7
Installation Instructions No. 01 29 9 416 445 Issue date: 1.2002
5. To install the rear right level sensor

2 Secure the holder for the level sensor to the holes

(1) on the frame. Secure the holder for the angle
1 joint to the holes (2) in the rocker arm.
Use the recess (3) to ensure that the angle joint can
move freely."

046 0929 V
0

3 Screw the holder (1) to the holes on the frame using two
0

4 hexagonal screws M6x12 with washers (2).

Secure the level sensor (3) to the holder (1) using two pan
2 head screws M5x10 (4) (check the coding on the level
sensor, see magnified view).
Secure the holder (5) to the hole in the rocker arm using
6 5 a hexagonal screw M6x16 (6) and a self-locking nut M6.
Screw the angle joint (7) to the holder (5) using the self-
locking hexagonal nut M6.
7 Connect the lever on the level sensor (3) and the angle
1 9 joint (7) using the extension (8) and secure it with two
8 9 self-locking nuts M6 (9).

046 0930 V

Retrofit kit No. 63 12 9 416 523 (others see cover sheet) EN/8
Installation Instructions No. 01 29 9 416 445 Issue date: 1.2002
6. To install the xenon headlights and connect the bi-xenon light adapter cable

If a headlight cleaning system (SRA) also has to be installed in the car the xenon headlights must be
installed in conjunction with retrofitting the SRA."
0

Remove the headlights using the current repair manual

0

and refit the headlight cleaning jets (1) to the supplied

xenon headlights (2).
1 Install the xenon headlights (2) and connect the SRA
hose line (3).
3
2

046 0931 V
0

Check the pin assignment of the 2-pin grey

connection plugs X130 (left) and X135 (right) for
the dipped headlights and change it if necessary."
The pins on the 2-pin grey connection plugs X130 and
X135 must have the following assignments:
1 2
Pin 1 (1): Earth (BR cable).
Pin 2 (2): Power supply (GE/GN cable (left) or GE/BL cable
(right)).

046 0932 V
0

BMW 3 Series Compact (E46/5) and BMW 3 Series

0

(E46) from 09/2001 only:

When you connect the bi-xenon headlights the adapter
cables supplied in the parts kit must be inserted between
the plugs X134 (full beam headlight, right) and X131 (full
beam headlight left) on the standard wiring harness and
the full beam headlight connectors (1) on the headlights.
The free plugs X10106 and X10107 on the adapter
cables are to be connected to the corresponding
1 connections (2) on the bi-xenon headlights.

2
046 0933 V The figure shows the bi-xenon headlights on the
BMW 3 Series Compact (E46/5), on other models
the positions of the connectors (1) and (2) may
differ slightly."

Retrofit kit No. 63 12 9 416 523 (others see cover sheet) EN/9
Installation Instructions No. 01 29 9 416 445 Issue date: 1.2002
7. To install the xenon wiring harness and replace the light module

Lay the cables on the xenon wiring harness along the standard wiring harness and secure them so that
they do not interfere with any other components and do not cause any rattling noises."
0

All branches are to be laid from the right-hand

footwell. "

Only for LHD cars:

In the right-hand footwell, branches A1 to A6 are to be
routed behind the relay holder (1) to the left, branches B1
1 to B3 and C1 to C3 are to branch off in the area of the A
C1-C3 pillar.
Branches A1, GR/WS cable, A2, GR/GN cable, A3, GR/
B1-B3 BR cable, A4, SW/GR cable, A5, SW/GN cable and A6,
A1-A6 SW/WS cable are to be routed from the A pillar in the right
046 0934 V footwell behind the relay holder (1) to the left, through the
corrugated tube to the driver's side and along the
standard wiring harness to the light module.

Only for RHD cars:

All branches are to branch off in the area of the A pillar.
Branches A1, GR/WS cable, A2, GR/GN cable, A3, GR/
BR cable, A4, SW/GR cable, A5, SW/GN cable and A6,
SW/WS cable are to be routed along the standard wiring
harness to the A pillar in the right-hand footwell to the
light module.

Tie back the excess length of branches A1 to

0
A6."
0

Figure 046 0935 V shows the light module in LHD

cars. In RHD cars, the light module is located on the
1 right-hand side; carry out the work in exactly the
same way."
Unclip the trim on the dashboard, unscrew the securing
screws (1) for the light module (2) and pull out the light
module (2).

046 0935 V

Retrofit kit No. 63 12 9 416 523 (others see cover sheet) EN/10
Installation Instructions No. 01 29 9 416 445 Issue date: 1.2002
7. To install the xenon wiring harness and replace the light module

Figure 046 0936 V shows the light module in LHD

cars. In RHD cars, the light module is located on the
right-hand side; carry out the work in exactly the
same way."
Disconnect the 54-pin plug X12 (1), remove the light
module and dismantle the 54-pin plug X12 (1).

1 The light module is no longer required."

Connect branches A1 to A6 on the xenon wiring harness

as follows:
046 0936 V
Connect branch A1, GR/WS cable, to slot 19 of the
54-pin plug X12 (1).
Connect branch A2, GR/GN cable, to slot 22 of the
54-pin plug X12 (1).
Connect branch A3, GR/BR cable, to slot 23 of the
54-pin plug X12 (1).
Connect branch A4, SW/GR cable, to slot 26 of the
54-pin plug X12 (1).
Connect branch A5, SW/GN cable, to slot 14 of the
54-pin plug X12 (1).
Connect branch A6, SW/WS cable, to slot 46 of the
54-pin plug X12 (1).

Assemble the 54-pin plug X12 (1), connect it to the new

light module and secure it.
Install the light module, secure with the screws and clip in
0
the trim.
Route branches B1, GR/WS cable, B2, GR/GN cable and
0

B3, GR/BR cable through the grommet from the right-

hand footwell into the engine compartment, continue
along the MacPherson strut tower through the cable
passage (1) into the wheel arch.

B1-B3
1

046 0937 V

Retrofit kit No. 63 12 9 416 523 (others see cover sheet) EN/11
Installation Instructions No. 01 29 9 416 445 Issue date: 1.2002
7. To install the xenon wiring harness and replace the light module

Attach branches B1, GR/WS cable, B2, GR/GN cable and

0

B3, GR/BR cable to the clips (1) close to the cable

passage (2).

1 2 Connect branches B1 to B3 to the 6-pin socket casing

X1451 (3) as follows:
Connect branch B1, GR/WS cable, to slot 1 of the 6-pin
B1-B3 socket casing X1451 (3).
Connect branch B2, GR/GN cable, to slot 4 of the 6-pin
socket casing X1451 (3).
Connect branch B3, GR/BR cable, to slot 5 of the 6-pin
3 socket casing X1451 (3).
Seal slots 2, 3 and 6 with the supplied blind grommets.
046 0938 V Secure the blade terminal contacts with the pink
retainers.

Connect socket casing X1451 (3) to the level sensor at

0
the front right.
All models apart from the BMW 3 Series compact
0

1 (E46/5):
C1-C3 Route branches C1, SW/WS cable, C2, SW/GN cable
and C3, SW/GR cable from the right-hand footwell along
the door sill wiring harness towards the back and
continue along the battery cable through the cable
passage (1) into the boot.

046 0939 V
0

Attach the supplied grommet D, secure it with insulating

0

tape and use it to replace the sealing stopper on the boot

floor.

C1-C3

F 46 0091 EVA

Retrofit kit No. 63 12 9 416 523 (others see cover sheet) EN/12
Installation Instructions No. 01 29 9 416 445 Issue date: 1.2002
7. To install the xenon wiring harness and replace the light module

BMW 3 Series compact (E46/5) only:

0

Route branches C1, SW/WS cable, C2, SW/GN cable

and C3, SW/GR cable from the right-hand footwell along
the door sill wiring harness towards the back and
continue along the standard wiring harness behind the
right-hand boot trim. Branches C1 to C3 run downwards
C1-C3 behind the trim.
Attach the supplied grommet D, secure it with insulating
D tape and use it to replace the sealing stopper on the boot
floor.

F 46 0750 EVA
0

All models apart from the BMW 3 Series compact

0

(E46/5):
C1-C3 Thread branches C1 to C3 between the plastic cover (1)
and the underbody and secure it to the frame using a
cable tie with a clip (2).

2 1

046 0940 V
0

All models:
0

Route branches C1 to C3 above the frame to the level

C1-C3 sensor and secure them with a cable tie (1).

Connect branches C1 to C3 to the 6-pin socket casing

X13251, C as follows:
C Connect branch C1, SW/WS cable, to slot 1 of the 6-pin
socket casing X13251, C.
1 Connect branch C2, SW/GN cable, to slot 4 of the 6-pin
socket casing X13251, C.
Connect branch C3, SW/GR cable, to slot 5 of the 6-pin
socket casing X13251, C.
046 0941 V Seal slots 2, 3 and 6 with the supplied blind grommets.
Secure the blade terminal contacts with the pink
retainers.

Connect the 6-pin socket casing X13251, C to the level

sensor at the rear right.

If you also have to retrofit a headlight cleaning

system (SRA) on the car, now install the SRA wiring
harness."

Retrofit kit No. 63 12 9 416 523 (others see cover sheet) EN/13
Installation Instructions No. 01 29 9 416 445 Issue date: 1.2002
8. To affix the warning sticker and assemble the car

Clean the cross member near the headlights and affix the
0

warning sticker
Licht aus! Bedien. Anltg.
Lights off!
iApagar la luz!
Manual
Instrucciones
Reassemble the car by following the instructions for its
25 000 V
Eteindre la lumière! Instruction
dismantling in reverse order.

F 46 0751 EVA

Retrofit kit No. 63 12 9 416 523 (others see cover sheet) EN/14
Installation Instructions No. 01 29 9 416 445 Issue date: 1.2002
9. Coding

This retrofit system requires coding.

The coding is necessary to ensure that the retrofit system is fully functional and does not cause malfunctions
and faults in combination with other electrical vehicle systems.

In addition the retrofit system is stored in the central coding key of the IKE/instrument cluster.

The coding process is completed using the DIS/MoDiC and is completed automatically using the current
coding program in the “Retrofit” path.
The procedure is user-guided, simply follow the text instructions to complete the various steps.

Print out the error memory and conduct a function test.

Retrofit kit No. 63 12 9 416 523 (others see cover sheet) EN/15
Installation Instructions No. 01 29 9 416 445 Issue date: 1.2002
10. Function test

When the dipped headlight switch is activated the headlights must adjust automatically."

Test the function of the automatic headlight adjustment control by loading the front and then the rear of the
car (delay approx. 15 seconds).

Retrofit kit No. 63 12 9 416 523 (others see cover sheet) EN/16
Installation Instructions No. 01 29 9 416 445 Issue date: 1.2002
11. To adjust the headlights

Check the default setting of the headlights on the basis of the manufacturer’s information and adjust them if
necessary.

Retrofit kit No. 63 12 9 416 523 (others see cover sheet) EN/17
Installation Instructions No. 01 29 9 416 445 Issue date: 1.2002
12. Circuit diagram

A3
HSSV HSGV HSPV HSSH HSGH HSPH
22 19 23 14 46 26
X12

0,5 0,5 0,5 0,5 0,5 0,5

x x x x x x
GRGN GRWS GRBR SWGN SWWS SWGR

X1451 X13251
4 1 5 4 1 5
HSSV HSGV HSPV HSSH HSGH HSPH

B42 B64

F 46 0108 EVA

Legend

A3 Light module
B42 Level sensor front, headlight adjustment control
B64 Level sensor rear, headlight adjustment control
X12 54-pin plug on light module
X1451 6-pin socket casing, level sensor front, headlight adjustment control
X13251 6-pin socket casing, level sensor rear, headlight adjustment control

Cable colours
0

GR grey
WS white
GN green
BR brown
SW black
GE yellow
BL blue

Retrofit kit No. 63 12 9 416 523 (others see cover sheet) EN/18
Installation Instructions No. 01 29 9 416 445 Issue date: 1.2002