Z3
Repair Instructions for Z3Vehicles concerned:
Z3
Manufacturing period: Start of series production (June 1995) to end of series production (June 2002)
Procedure:
1. Connect BMW diagnostic system (DISplus or GT1) to the vehicle.
2. Read off fault memory.
The following fault codes may be stored in the airbag control unit fault memory:
^ "05 - Driver-side belt tensioner triggering circuit"
^ "06 - 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 1 (order no. 61 9 029).
A conventional workshop hot-air blower is also required.
Remove the front seat concerned.
Release cable tie (1) and unplug connector (2) with cover. Remove seat wiring harness of belt tensioner or unpin or cut off seat connector of seat wiring-harness.
Plug connector (1) of repair wiring harness section and cover on to belt tensioner. Secure the connector (1) and the cover with a cable tie (2).
Important:
Repair wiring harness section must be routed and secured so that it is free of tension.
Secure repair wiring harness section with two cable ties (2) in loops as illustrated underneath the seat upholstery. Connect plug (3) to support bracket.
Note:
The procedures in these repair instructions may deviate from the "Airbag lead repairs".
Prepare the second repair wiring harness section (1) for installation 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 repair wiring harness section (2) to the plug-in connection already fitted.
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 fabric tape (1) on vehicle wiring harness and slide back insulating tube (2) by approximately 300 mm.
If necessary unplug the twisted ignition circuit wires from the connector on the vehicle wiring harness.
Shorten yellow/brown triggering circuit wire by 250 mm and yellow/red triggering circuit wire by 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.
Butt connector for repairing connector
Slide insulating sleeve (1) over the repair and fix to the vehicle wiring harness (2) with a fabric tape.
Install the front seat concerned.
5. Connect vehicle battery
6. Clear the fault memory
Parts
Reimbursement