Recall 09V-257 - Repair Air Bag Harness: Overview
SI B65 24 09Audio, Navigation, Monitors, Alarms, SRS
March 2011
Technical Service
This Service Information bulletin supersedes SI B65 24 09 dated September 2009.
PERFORM THE PROCEDURE OUTLINED IN THIS SERVICE INFORMATION ON ALL AFFECTED VEHICLES BEFORE CUSTOMER DELIVERY OR THE NEXT TIME THEY ARE IN THE SHOP FOR MAINTENANCE OR REPAIRS.
Under the National Traffic and Motor Vehicle Safety Act of 1966, as amended, if there has been a recall campaign, dealers must assure that all new vehicles and new items of replacement equipment are free of safety defects and comply with all applicable Federal Motor Vehicle Safety Standards at the time of delivery to the consumer. This means that dealers may not deliver new motor vehicles or new items of replacement equipment to consumers unless the safety defect or noncompliance has been remedied before delivery.
[NEW] designates changes to this revision
SUBJECT
Recall Campaign 09V-257: Repair Airbag Harness
MODEL
E82, E88 (1 Series)
[NEW] E90, E92, E93 (3 Series)
SITUATION
There may be incorrect wiring crimps in the airbag harness at the plug connectors located under the front seats. This wiring affects the seatbelt tensioner and front side airbag circuits.
The crimps may fail, causing the airbag warning lamp in the instrument cluster to be illuminated. In this case, the front side airbag or seat belt tensioner may not deploy in the event of an accident.
A copy of the customer notification letter is attached.
AFFECTED VEHICLES
This Recall Campaign involves E82 and E88 (1 Series), and E90, E92 and E93 (3 Series) vehicles which were produced from May 23, 2008 to July 21, 2008.
In order to determine whether a specific vehicle is affected by this Service Action, it will be necessary to utilize the "Service Menu" of the DCS (Dealer Communication System) or the Key Reader. Based on the response of the system, either proceed with the corrective action or take no further action.
PROCEDURE
1. Follow airbag safety instructions REP 72 00...
2. The procedure must be carried out on both driver and passenger seat connectors.
3. Move both the driver and passenger seats to the full rearwards and upwards position.
4. Unlock and disconnect the now visible plug connectors (1) and (2) beneath the driver's seat and front-passenger's seat.
5. Cut the cable tie (1) and remove the connector housing (2).
Note:
Be sure to replace the cable tie when the repair operation is completed.
6. Remove the fabric tape (1) and push back the protective sleeve.
7. Carry out a visual inspection of the driver's side and front-passenger side to see if one or both of the cable harnesses have already been repaired. In the case of a wiring repair, the wire colors in pin locations 16, 17, 19 and 19 will be orange/yellow.
8. For harnesses NOT previously repaired, follow the repair procedure from step 9.
9. Using the airbag repair cable, select the end with the green rubber seals (1).
10. Cut each twisted wire pair to length A = 11 cm*.
* Length is approximate. The cuts may be staggered in order to achieve a neater repair.
11. Remove the wires (1) and (2) from the connector locations 18 and 19 (twisted pair wires). (Pin 19 is shown already removed.)
12. Cut the wires at a point B = 11 cm* from the end of the terminals.
* Length is approximate. The cuts may be staggered in order to achieve a neater repair.
13. Strip 3 mm of insulation from each of the wire ends, then connect each of the cut wires of the existing harness (1) to the wires from the airbag repair cable (2) using a buff connector (3). Double crimp (wire crimp and insulation crimp) each wire to the butt connector using the universal crimping die P/N 61 4 328 (refer to SI B04 32 06).
14. With the heat shrink (4) positioned over the butt connector, use a heat gun to seal the splice.
IMPORTANT:
Use caution; do not burn the shrink tubing or the harness insulation.
15. As each splice is completed, for ease of reassembly, mark the repair cable wire to identify its connector location.
16. Using special tool 61 0 327, reinstall the wires into their correct locations in the plug connector. If possible, maintain the wires as twisted pairs. For reference, use the chart above.
17. Remove the wires (1) and (2) from the connector locations 16 and 17 (twisted pair wires). (Pin 17 is shown already removed.)
18. Cut the wires at a point B = 11 cm* from the end of the terminals.
* Length is approximate. The cuts may be staggered in order to achieve a neater repair.
19. Repeat steps 9-16.
20. Retape the harness, using fabric tape. Pull the protective sleeve back into position and tape the end for a neat repair.
21. Reinstall the connector housing and retain the harness with the cable tie (see step 5).
22. Repeat the repair procedure for the seat harness on the other side of the vehicle.
23. Using the BMW diagnostic equipment, perform a vehicle test and a quick delete to confirm a satisfactory repair.
PARTS INFORMATION
LABEL INSTRUCTIONS
This Recall Campaign has been assigned code number 545. After the vehicle has been checked and/or corrected, obtain a label (SD 92-366) and:
A. Emboss your BMW center warranty number in the middle of the label (1);
B. Punch out code number 545 (2), printed on the label; and
C. Affix the label to the B-pillar as shown.
If the vehicle already has a label from a previous Service Action/Recall Campaign, affix the new label next to the old one. Do not affix one label on top of another one, because a number from an underlying label could appear in the punched-out hole of the new label.
WARRANTY INFORMATION
ATTACHMENTS
B652409 QUESTIONS AND ANSWERS