Restraint Systems - Air Bag Lamp ON/Multiple DTC's Set
SI M 72 01 03Safety Restraint Systems
September 2003
Service Engineering
SUBJECT
Airbag Warning Light is ON, MRS FC 02, 03, 05, 06
MODEL
R50, R53 (Cooper, Cooper S) up to January 2003 Vehicle Production
SITUATION
The Customer may complain that the airbag warning light is on, and the following faults are stored in the MRS (Multiple Restraint System) control unit:
^ 02 - Driver's side belt tensioner ignition circuit
^ 03 - Passenger's side belt tensioner ignition circuit
^ 05 - Driver's side seat airbag ignition coil
^ 06 - Passenger's side seat airbag ignition coil
CAUSE
^ Increased resistance at the contacts of the seat connectors due to contamination.
^ Faulty crimping of contacts at the seat connectors.
PROCEDURE
In case of a customer complaint and one of the faults mentioned above is stored, replace the wiring to the respective belt tensioner and side airbag for the seat with the repair harnesses as follows. Always comply with the safety instructions when handling airbag devices as outlined in the repair manual RA 32 34...
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.
1. Disconnect the battery
2. Remove the front seat with the stored fault.
3. Install the new cable tie with holder (1) (PN 61 13 0 302 824) and fit to the carrier (2). Remove the cable tie for later use.
4. Release the connector housing (1) by turning it slightly.
5. Release the seat wiring harnesses (2) for the side airbag and seat belt tensioner from the retainers (3).
Preparing seat wiring harnesses for repair
6. Shorten the outer sheath (3) of the seat wiring harnesses by approximately 150 mm from the connector housings. Take care not the cut the wiring. Seal the outer sheaths to the wires using fabric adhesive tape.
7. Cut the seat wiring harnesses for side airbag (1) and belt tensioner (2) to offset lengths with the following dimensions:
Seat wiring harness for side airbag (1):
Violet/white triggering circuit wire A = 130 mm
Black/white triggering circuit wire B = 100 mm
Seat wiring harness for belt tensioner
(2):
Green triggering circuit wire A = 130 mm
Black triggering circuit wire B = 100 mm
8. Strip the ends of the triggering circuit wires on the seat wiring harnesses to a length of 4 mm. Install shrink tube (1) (PN 61 13 0 149 206) over the wires.
9. Swap over the retainer clips from the old harness connectors to the new repair harness connectors
10. Connect the repair harness sections (1) and (2) together for both the seat side airbag repair harness (PN 61 12 6 937 521) and the seat belt tensioner repair harness (PN 6112 6 937 522). Fold the repair harness sections (1) and (2) at the connection to form an S" shape. Secure with cable ties (3) (PN 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.
11. 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.
12. 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.
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
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
13. Strip the ends of the shortened triggering circuit wires on the repair harnesses to a length of 4 mm.
14. Crimp a buff connector (1) (PN 61 13 0 149 205) to each seat wiring repair harness (2) wire.
15. 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.
16. 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.
17. Using fabric adhesive tape wrap the exposed harness.
18. Press the wiring harnesses into the retainer as indicated by arrow.
19. Secure the connector for the belt tensioner (1) and side airbag (2) onto carrier.
20. Secure the repair wiring harnesses to the retainers (3) with cable ties.
Preparing the repair wiring harnesses for connection to the body wiring harness.
21. Shorten the repair wiring harness for side airbag (1) and seat belt tensioner (2) as follows:
22. Shorten the outer sheaths of the repair wiring harnesses to A = 150 mm
23. 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
24. Strip the ends of the shortened triggering circuit wires on the repair harnesses to a length of 4 mm.
25. Crimp a butt connector (1) (PN 61 13 0 149 205) to each seat wiring repair harness (2) wire.
Preparing the body wiring harness for repair.
26. Remove fabric adhesive tape (1) from the vehicle wiring harness and slide back sheathing (2) by approximately 300 mm.
27. Fix sheathing in place with cable tie or fabric adhesive tape.
28. 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 = 150 mm
Yellow triggering circuit wire B = 180 mm
Drivers side body wiring harness for belt tensioner (2):
Yellow/Brown triggering circuit wire C = 210 mm
Yellow/Red triggering circuit wire D =
240 mm
Passenger side body wiring harness for belt tensioner (2):
Blue/Brown triggering circuit wire C = 210 mm
Blue/Red triggering circuit wire D = 240
29. Strip a length of 4 mm from at the end of each wire.
30. Slide a shrink tube (1) over each wire.
Connecting the repair wiring harness to the body wiring harness.
31. Place the seat in the vehicle and tilt back towards the rear seat.
32. Crimp the wiring harnesses (1) together in accordance with the attachment Chart B.
33. 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, indicate by arrows.
34. Slide the wire sheathing (1) over the wiring harness and secure with fabric tape (2).
35. Reinstall the front seat.
36. Reconnect battery.
37. Clear fault memory.
PARTS INFORMATION
WARRANTY INFORMATION
Covered under the terms of the BMW New Vehicle Limited Warranty.
ATTACHMENTS
view PDF attachment M720103Attachment.
Chart A: Color allocation of triggering circuit wires of seat wiring harness and repair wiring harness
Chart B: Color allocation of triggering circuit wires of body wiring harness and repair wiring harness