Trunk Lock/Door Locks/Windows/Gauges - Inoperative
Group 61General Electrical Systems
Bulletin Number
61 O2 99
Woodcliff Lake, NJ
April 1999
Product Engineering
SUBJECT:
Trunk Harness Cut or Broken at Hinge
MODEL:
Z3 roadster, M roadster
Complaint:
A cut, or broken trunk harness my cause the following complaints: trunk lock motor inoperative, power locks and windows inoperative, no start, or fuel gauge/clock/board computer inoperative.
Cause:
Poor routing of the harness through its clip at the trunk hinge, causes the trunk hinge mechanism to cut or damage the harness, or causes the harness wires to fatigue due to constant bending.
Correction:
On a customer complaint basis, install a new trunk harness.
Procedure:
1. Disconnect the battery.
2. Remove the carpet from the left side of the trunk.
3. Locate the trunk harness as it comes out of the sheathing (1) in the left side of the trunk. Using a utility knife, carefully cut the harness tape approximately 6" from the sheathing. Take care not to cut through the wire insulation.
4. Unwrap the tape back to the sheathing (1).
5. Separate the two wire harness (2) (red/white, brown/white wires) from tine main trunk harness, and pull it away, so that it is not cut by mistake.
6. Cut the trunk lid harness - approximately 1" from the end of the sheathing (1).
If in doubt, check the wire colors. Wires to be cut are: blue/red, brown x 2, white, blue/gray, red/green, white/green/yellow, white/blue, brown/white. There are two additional wires on the M roadster: gray/black, and brown.
7. Unclip plastic covers (1), (2) and (3) under the trunk lid to give access to the trunk harness, and unplug trunk harness connectors. Before removing the damaged harness from the trunk lid, attach a fishing wire to each connector (4) and (5). The fishing wires can then be used to pull the new hamess into position.
Remove the trunk harness through hole (6), untie the fishing wires, and put the harness aside.
8. Strip 1/4" insulation from the end of each wire cut in step 6.
9. Double crimp (wire crimp (1) and insulation crimp (2)) a female terminal (supplied with repair harness) to each wire.
10. Assemble the terminals to the 12 pin socket housing (1) supplied with repair harness as follows:
Pin 1 blue/red
Pin 2 brown
Pin 3 white
Pin 4 blue/gray
Pin 5 red/green
Pin 6 white/green/yellow
Pin 7 white/blue
Pin 8 brown
Pin 9 brown/white
Pin 10* gray/black
Pin 11* brown
Pin 12 (2) not used
* M roadster only
11. Install the trunk repair harness in the trunk lid1 using the fishing wires (step 7) to pull the harness into position. Route the harness via the hinge area to the point where the original harness was cut. Reconnect the connectors in the trunk lid, and tie back any that are not used.
12. Connect the connector on the repair harness (2) to the socket housing (1) installed to the main harness in the trunk.
13. Position the harness in the plastic clip at the hinge in such a way that it does not get trapped by the trunk hinge stop when the trunk lid is in the closed position. If required, adjust the length of the harness in the hinge area, or rotate the grommet on the body side of the hinge to get the best possible position.
14. Reconnect the battery, and check all trunk lid electrical functions.
Parts Information:
Part Number Description Qty
6110 8 385 924 Wiring harness repair kit 1
Warranty Information:
Covered under the terms of the BMW new car limited warranty.
Defect Code: 6111 91 69 00
Labor Operation: Remove and replace trunk harness
Labor operation Labor Allowance
Main Work 6112 135 10 FRU (Z3 roadster)
11 FRU (M roadster)
Associated Work +6112634 8 FRU (Z3 roadster)
10 FRU (M roadster)
Note:
The following explanations will spell out the correct use of the work times.
Main Work:
Use this labor operation number when the only repair performed is the listed warranty repair.
OR
+Associated Work:
Use this labor operation number when other repairs or services are performed along with the listed warranty repair.
Under no circumstances should both labor operation numbers be claimed. Attempts to claim both times will result in an unnecessary delay in claim processing and payment.