Procedure A - E60 (5 Series) Only

1. Completely remove all the round latch clips from the foam and the flexmat. Remove all pieces of round latch clips, as these will cause rattling noises.

2. Loosen the foam with backrest cover from the backrest frame and fold it towards the center of the vehicle. The backrest cover remains attached at the bottom on the tunnel side. Removal without care could result in irreparable damage. The backrest heating wiring harness may be secured to the backrest frame by cable straps. These straps must be removed and replaced with new ones when the seat is reassembled.





3. Afier removing all of the round latch clips, detach the backrest cover (1) from the foam pad. The cover will remain attached on the inboard side of the seat. Note: Passenger seat shown for the E60 (5 Series) repair.





4. Fold down the cotton fabric (1) to gain access to the heating fleece.

On the E60 (5 Series) Basic seat, it may be necessary to partially detach the heating fleece from the leather by cutting along the outboard seam using a seam ripper (2). Note: Be careful not to cut the stitching that holds the leather seems together.





5. Fold the heating fleece (1) over to gain access to the opposite side.





6. Mark the following dimensions on the heating fleece:

Note:
Place a light behind the heating fleece to verify the location of the metal strands. Ensure that dimension A3 will completely cross the metal strands.
A1: approximately 60 mm (from the upper seam).
A2: approximately 30 mm for a basic seat or approximately 10 mm for a sports seat (from the door-side seam).
A3: approximately 20 mm (from dimension A2).





7. Cut open the heating pad along the marking made for dimension A3 to expose all 11 metal strands (1). This cut can be made using a razor or a seam ripper.

Note:
The heating fleece consists of3 plies. Be careful when cutting along dimension A3 to only cut into the first ply. The metal strands are bonded to the second ply of the heating fleece.





8. From the corners of the cut made for dimension A3, cut parallel incisions (1) to the left and right of the metal strands (A4) using a seam ripper.

Note:
Place a light behind the heating pad to verify the location of the metal strands. Be careful when cutting along dimension
A4 to only cut into the first ply.
A4: approximately 50 mm long.





9. Peel back the first ply (1) of the heating fleece 50 mm to expose the metal strands.





10. Use a razor (1) or a seam ripper to cut across the 11 strands by following the same cut made for dimension A3.
Note: A splice into these metal strands will be performed in a later step. Be sure this splice will connect to the wiring going downwards through the seat.

11. Using the blunt side of the seam ripper (2), carefully pull up on each metal strand (1) to release them from the fabric threads. Start pulling up on the metal strands near the cut made for dimension A3. Continue downwards until 50 mm of the metal strands have been released from the fabric threads.

Note:
The metal strands remain attached to the fleece near the bottom fold of the first ply.
Be careful not to damage the metal strands when pulling them away from the threads. It may be necessary to cut some of the treads to release the metal strands.





12. Once the 11 metal strands are released from the second ply of material, fan out the strands to make them ready to splice with the wire from the repair kit.





13. Strip the wire (1) from the repair kit (copper-colored end) and fan out the strands. Join the copper strands to the 11 metal heating strands and twist them together.





14. Twist the wires together tightly to form one slender splice of both sets of wires.





15. Push the end sleeve (1), from the repair kit, over the twisted splice.





16. Crimp (1) using special tool (2) number 52 0 100. Cut off the protruding strands approximately 5 mm from the end of the sleeve.





17. Cut and remove the second ply of the heating fleece by following the edges of the cuts made for dimensions A3 and A4.

18. Affix the small fleece adhesive strip (1) (60 mm x 40 mm), from the repair kit, over the padding where the cuts were made.

19. Make a 10 mm cut (2) across the center of the installed fleece strip to make it possible to route the wire through at a later stage.





20. Using a hot glue gun, apply glue to the center of the small fleece adhesive strip (1) and affix crimped strands to the glue. To secure, press a hammer (2) onto glue for at least one minute. Pull the wire (3) through the cut prepared in step 19 (4). Cut a small hole on the opposite side of the fleece padding to route the wire through. Note: Do not use an excessive amount of glue and be sure to press firmly with the hammer. Failure to do so may result in a bump in the leather when the procedure is completed.





21. Affix another small fleece adhesive strip (60 mm x 40 mm) (1) over the repair area under the U-section.





22. Fold the first ply (1) of the heating fleece back over the repair area and seal the repair area with the large fleece adhesive strip (170 mm x 55 mm) (2) provided in the repair kit.

23. Continue to procedure D: For All Seats.