E38 and E39
Repair Instructions for E38, E39Vehicles concerned:
E38, E39
Manufacturing period:
E38: Start of series production until January 2002.
E39: Start of series production until March 2004
Procedure:
1. Connect BMW diagnostic system (DiSplus or GT1) to the vehicle.
2. Read off fault memory.
The following fault codes could be stored in the fault memory of the airbag control unit, depending on manufacturing period and model:
E38, E39 to March 1999
^ "05 - Driver-side belt tensioner triggering circuit"
^ "06 - Passenger-side belt tensioner triggering circuit"
E38, E39 from March 1999
^ "02 - Driver-side belt tensioner triggering circuit"
^ "03 - Passenger-side belt tensioner triggering circuit"
3. Disconnect the vehicle battery.
4. Fit repair wiring harness.
Important:
Comply with safety instructions when handling airbag modules and pyrotechnic belt tensioners.
The minimum transition resistance must be achieved when the repair wiring harness is fitted. For this reason, it is essential that the hotspots in the Repair Instructions are observed.
Service Information bulletin SI 61 01 99 (397) "Airbag, Repair Instructions for triggering circuits" remains valid for damaged or defective wires and connectors in the triggering circuits of the airbag system.
The following special tools from repair set IV for vehicle electrics (order no. 61 9 020) are needed for professional repairs on the wiring:
- Hand-held stock (without die) (order no. 61 9 041)
- Die for hand-held stock (order no. 61 9 042)
- Insulation strippers (order no. 61 9 043)
Note:
All instructions needed on using the special tools are described in the Operating instructions/volume (order no. 61 9 029).
A conventional workshop hot-air blower is also required.
Remove the front seat concerned.
Remove inner seat cover (1).
If necessary, separate cable strap (2).
Unclip cover (3).
Unlock and separate connector (1) on the belt tensioner.
Partially strip wiring harness (1).
Cut the two black triggering circuit wires (2) for the angled belt tensioner connector.
Tape the wiring harness back together with fabric adhesive tape.
Connect the repair wiring harness sections with the connector and feed into the opening on the side of the seat.
Plug angled connector (4) onto the belt tensioner and lock.
Secure repair wiring harness section (2) and wiring harness (1) with cable strap (3).
Clip on cover (1) and press wiring harness (3) into retainer.
Secure repair wiring harness (4) to cover (1) and belt tensioner with cable strap (2).
Install seat cover (5).
Important:
Repair wiring harness section (1) must be routed and secured so that it is free of tension.
Route repair wiring harness section (1) under the seat and into the cable ties (2) in the order shown.
Fold the repair wiring harness sections (1) and (2) at the connection to form an "S" shape and secure with cable ties (3).
When securing the "S" shape, the crossed cable ties (3) must securely connect the repair wiring harness sections to the connector housing.
Secure S" shape (1) to plastic cover (2) of central seat connector with a cable strap (3).
Prepare the repair wiring harness as follows:
Cut the blue wire on the repair wiring harness section (1) to different lengths (A = approximately 30 mm).
Strip 4 mm at the ends of the wires.
Cutting and stripping wires
Crimp-connect butt joint (1) for wire cross-sections of 0.35 to 0.50 mm2 to the two stripped ends of repair wiring harness section (2).
Crimping buffer pieces
Connect the butt connector on the repair wiring harness section (4) to the BMW diagnostic system through multifunction cable 1 (MFK 1):
(1) MFK 1 from BMW diagnostic system
(2) Double-ended banana plug
(3) SAGK4 tapping clips, black and red (DIS measuring probe set 61 1 410)
(4) Repair wiring harness section
On the BMW diagnostic system, select "Multimeter" measuring method with resistance/ohms submenu.
Read off measured value.
Setpoint value: 1 to 6 ohms
Note:
If the setpoint value is not achieved, replace the belt tensioner and return the removed part together with the tester printout.
Continue fitting the repair wiring harness.
Place the front seat in the vehicle and tilt it back to the rear seat.
Remove the cover cap from connector housing (1) on the vehicle wiring harness and remove the twisted belt tensioner triggering circuit wires (2) yellow/brown and yellow/red from the connector housing.
Close connector housing (1) again with the cover cap.
Remove the fabric adhesive tape from the vehicle wiring harness and slide back insulating sleeve (1) approximately 300 mm.
Cut the triggering circuit wires to different lengths with the following dimensions:
- yellow/brown triggering circuit wire A = 250 mm
- yellow/red triggering circuit wire B = 220 mm
Strip 4 mm of the triggering circuit wires.
Cutting and stripping wires
Slide heat-shrink sleeves (1) over the triggering circuit wires.
Crimp butt connector on repair wiring harness section (1) with triggering circuit wires.
- brown wire with yellow/brown
- Blue wire with yellow/red
Crimping buffer pieces
Slide heat-shrink sleeves (1) over the crimped connections and heat with hot-air blower until glue escapes onto the wires (arrows).
Butt connector for repairing connector
Slide insulating sleeve (1) over the repair and fix to the vehicle wiring harness (3) with a cable strap (2).
Connect seat connector (1).
Press wiring harness (2) into retainer (3) and close flap (4) on plastic cover.
Install the front seat concerned.
5. Connect vehicle battery
6. Clear the fault memory
Parts
Reimbursement