Procedure
PROCEDURENOTE:
Please be sure to follow the procedure as described below. Analysis of parts returned so far shows:
^ Connectors are being returned disconnected. (The connectors must remain connected: see steps 4 and 5.)
^ Connector wires are cut too close to the connector. (The wires must be cut 100mm from the connector: see steps 4, 5, 10 and 11.)
^ There is no DIS printout accompanying the returned parts. (A DIS printout, showing which connector failed and its fault codes, must be included.)
^ Connectors for one vehicle are being returned in more than one bag. (Place all connectors in one return bag.)
Failure to follow these procedures will result in the warranty claim being debited.
If one of the faults mentioned above is stored:
1. [NEW] Perform a vehicle test using ISTA/D (Integrated Service Technical Application) and complete all the corresponding test module-related fault codes and the printout that shows the failed connector and its stored fault codes. Then replace the wiring to the respective belt tensioner and side airbag for the seat with the repair harnesses, as described below.
2. [NEW] Disconnect the battery. Always comply with the safety instructions when handling airbag devices as outlined in ISTA Repair Instruction REP 72 00...
The following tools will be needed in order to perform this repair correctly:
^ Pliers (without die plate) 61 9 041
^ Die plate for pliers 61 9 042
^ Wire strippers 61 9 043
^ Hot air blower
3. Remove the (4) mounting screws from the front seat with the stored fault.
The illustration shows the (2) front screws.
4. Raise the seat at the front (1).
5. Locate the yellow side airbag connector (DO NOT DISCONNECT).
Cut the wire as shown, 100mm from the connector (A).
6. Locate the blue seat tensioner (DO NOT DISCONNECT).
Cut the wire as shown, 100mm from the connector (A).
7. Disconnect the remaining connectors (4) and (5), and remove the seat from the vehicle. Connector (4) may not be on all vehicles.
8. Install the new cable tie with holder (1) (P/N 61 13 0 302 824) and fit to the carrier (2). Remove the cable tie for later use.
9. Release the connector housing (1) by turning it slightly.
10. Release the seat wiring harnesses (2) for the side airbag and seat belt tensioner from the retainers (3).
11. Locate the yellow side airbag connector (2). Cut the wire as shown, 100mm from the connector (A).
Tag the removed part with the VIN. Do not scrap the removed part; it may be necessary to ship the part to BMW for analysis (DO NOT DISCONNECT THE CONNECTOR).
12. Locate the blue seat tensioner connector (3). Cut the wire as shown, 100mm from the connector (A).
Tag the removed part with the VIN. Do not scrap the removed part; it may be necessary to ship the part to BMW for analysis (DO NOT DISCONNECT THE CONNECTOR).
[NEW] Mark the defective connector(s), and then put all the removed parts and ISTA printout together in a plastic bag.
Preparing seat wiring harnesses for repair
13. Shorten the outer sheath of the seat wiring harnesses by approximately 50 mm from the wire ends. Take care not to cut the wiring. Seal the outer sheaths to the wires using fabric adhesive tape.
14. Cut the seat wiring harnesses for the side airbag (1) and belt tensioner (2) to offset lengths with the following dimensions (cut only [1] wire of each wire pair):
Seat wiring harness for side airbag (1):
Violet/white triggering circuit wire A = 30 mm
Seat wiring harness for belt tensioner (2):
Green triggering circuit wire A = 30 mm.
15. Strip the ends of the triggering circuit wires on the seat wiring harnesses to a length of 4 mm. Install the shrink tube (1) (P/N 61 13 0 149 206) over the wires.
16. Swap over the retainer clips from the old harness connectors to the new repair harness connectors.
17. Connect the repair harness sections (1) and (2) together for both the seat side airbag repair harness (P/N 61 12 6 937 521) and the seat belt tensioner repair harness (P/N 61 12 6 937 522). Fold the repair harness sections (1) and (2) at the connection to form an "S" shape. Secure with cable ties (3) (P/N 61 13 0 141 326). Take care to note the position of the cable fasteners. Do not use Stabilant 22 or any other contact enhancer on the connections.
18. Shorten the outer sheaths of the repair wiring harnesses to B = 100 mm. Seal the outer sheaths to the wiring harnesses using fabric adhesive tape.
19. Cut the repair wiring harnesses for the side airbag (1) and the belt tensioner (2) to offset lengths with the following dimensions:
Note: the wire colors are different based on the date of manufacture of the repair harness.
Late production repair wiring harness
Repair wiring harness for side airbag (1):
Black/White triggering circuit wire A = 40 mm
Violet/White triggering circuit wire C = 70 mm
Repair wiring harness for belt tensioner (2)
Black triggering circuit wire A = 40 mm
Green triggering circuit wire C = 70 mm
Early production repair wiring harness
Repair wiring harness for side airbag (1):
Brown triggering circuit wire A = 40 mm
Yellow triggering circuit wire C = 70 mm
Repair wiring harness for belt tensioner (2)
Yellow/Brown triggering circuit wire A = 40 mm
Yellow/Red triggering circuit wire C = 70 mm
20. Strip the ends of the shortened triggering circuit wires on the repair harnesses to a length of 4 mm.
21. Crimp a butt connector (1) (P/N 61 13 0 149 205) to each seat wiring repair harness (2) wire.
22. Crimp the repair wiring harnesses to the seat wiring harnesses in accordance with the attachment Chart A. Make sure that the proper wire colors are used, based on the manufacturing date of the repair harness.
23. Slide the shrink tube (1) over the crimp connection and heat up with a hot air blower until glue escapes onto the wires, as indicated by arrows.
24. Using fabric adhesive tape, wrap the exposed harness.
25. Press the wiring harnesses into the retainer as indicated by the arrow.
26. Secure the connector for the belt tensioner (1) and side airbag (2) onto the carrier.
27. Secure the repair wiring harnesses to the retainers (3) with cable ties.
Preparing the repair wiring harnesses for connection to the body wiring harness
28. Shorten the repair wiring harness for the side airbag (1) and seat belt tensioner (2) as follows:
29. Shorten the outer sheaths of the repair wiring harnesses to A = 150 mm.
30. Cut the repair wiring harnesses for the side airbag (1) and belt tensioner (2) to offset lengths with the following dimensions:
Note:
The colors of the triggering circuit wires for the repair harnesses have not changed.
Repair wiring harness for side airbag (1):
Brown triggering circuit wire D = 50 mm
Yellow triggering circuit wire E = 80 mm
Repair wiring harness for belt tensioner (2):
Yellow/Brown triggering circuit wire B = 110 mm
Yellow/Red triggering circuit wire C = 140 mm
31. Strip the ends of the shortened triggering circuit wires on the repair harnesses to a length of 4 mm.
32. Crimp a butt connector (1) (P/N 61 13 0 149 205) to each seat wiring repair harness (2) wire.
Preparing the body wiring harness for repair
33. Remove the fabric adhesive tape (1) from the vehicle wiring harness and slide back the sheathing (2) by approximately 300 mm.
34. Fix the sheathing in place with a cable tie or fabric adhesive tape.
35. Cut the body wiring harness for the side airbag (1) and belt tensioner (2) to offset lengths with the following dimensions:
Body wiring harness for side airbag (1):
Brown triggering circuit wire A = 50 mm
Yellow triggering circuit wire B = 80 mm
Driver's side body wiring harness for belt tensioner (2):
Yellow/Brown triggering circuit wire C = 110 mm
Yellow/Red triggering circuit wire D = 140 mm
Passenger side body wiring harness for belt tensioner (2):
Blue/Brown triggering circuit wire C = 110 mm
Blue/Red triggering circuit wire D = 140 mm
36. Strip a length of 4 mm from the end of each wire.
37. Slide a shrink tube (1) over each wire.
Connecting the repair wiring harness to the body wiring harness
38. Place the seat in the vehicle and tilt back towards the rear seat.
39. Crimp the wiring harnesses (1) together in accordance with the attachment Chart B.
40. Slide the shrink tubing (1) over the crimp connections and heat up using a hot air blower until glue escapes onto the triggering circuit wires, indicated by arrows.
41. Slide the wire sheathing (1) over the wiring harness and secure with fabric tape (2).
42. Reinstall the front seat.
43. Reconnect the battery.
44. Clear the fault memory.