Enclosure 1 No Fuse Holder In Auxiliary Relay Box

Enclosure 1 to S.I. 61 03 90 (3053)


VEHICLES WITH NO FUSE HOLDER IN AUXILIARY RELAY BOX


Situation: A running change has been made to recent production 5 and 7 Series vehicles. As a result of this change, you may encounter vehicles in which the auxiliary fuse holder has been relocated from the auxiliary relay box into the main fuse box (power distributor).

This change makes it impossible to gain access to the fuse holder. The factory has been requested to move the unit back into ds original location.

If such a vehicle is encountered, all accessory wiring for KL15 and KL30 (except direct connection to the battery positive terminal) will have to be routed as outlined below. (KL30 = constant B+, KL15 B+ with ignition ON)

Note: Under no circumstances should an attempt be made to route accessory wiring into the fuse box (power distributor).

1. Disconnect battery.

2. Route accessory wiring across firewall to left side of vehicle.

3. Remove fuse holder from each accessory wire. Temporarily insulate end of wire to removed fuse holder wfth electrical tape (to prevent short circuits when connections to KL30 or KL15 are made).

4. Remove cover from auxiliary relay box.

5. Use wire harness grommet to access interior of auxiliary relay box.


CAUTION


Extreme care must be taken when routing wires through access holes/grommets in the vehicle. Never puncture seals or "snake" wires through grommets using sharp pointed instruments or tools! Doing so will compromise weather tightness of seals and may cause severe electrical problems resulting from corrosion and/or electrical shorts.
The auxiliary relay box contains the following relays:

K33 - air conditioning relay K21 - normal speed relay K22 - high speed relay

Each of these relays has a KL30 and/or KL15 circuit wired to it. Remove all relays and relay multiplugs from auxiliary relay box.

6. As needed, the accessory wiring can be connected to these circuits as follows:

KL30 (constant B+) red/green wire
KL15 (B+ with ignition ON) green/blue/yellow wire

Note: Do not use "quick-splice" methods such as 3M connectors to attach these wires. The only approved method of attachment is listed below.

7. Remove appropriate female spade connector from relay multiplug. Refer to instructions in "Attachment A".

8. Cut off existing female spade connector.

9. Strip original wire and accessory wire using BMW crimping pliers.

10. Using BMW crimping pliers, install new BMW connectors (P/N 61 13 1 370 693) onto the original and accessory wires crimping both wires into the new connector. Refer to "Attachment B".

All crimped electrical connections must be absolutely tight. When in doubt, solder the connection.

11. Install the new female spade connector into its original position in the relay multiplug and reassemble the multiplug.

12. Reinstall the relays and multiplugs previously removed.

13. Make certain weathertight seal of wire harness grommet has not been compromised. ff necessary use BMW glass sealing compound (P/N 81 22 9 400 013) to seal any air gaps where wires run through grommet.

14. Reinstall cover on auxiliary relay box.