1990 BMW 535iFACTORY OEM SERVICE PROCEDURE

Wiring Repair Procedure For Firing Circuits Of Airbag Systems; General Guidelines (61 02 00)

Publication date: 2000-04-01
Reference number: 61 02 00

WIRING REPAIR PROCEDURE FOR FIRING CIRCUITS OF AIRBAG SYSTEMS; GENERAL GUIDELINES

WIRING REPAIR PROCEDURE FOR FIRING CIRCUITS OF AIRBAG SYSTEMS; GENERAL GUIDELINES

TECHNICAL SERVICE BULLETIN

Reference Number(s): 61 02 00, Date of Issue:  April, 2000
BMW: All Models
GROUP: 61 - General Electrical System

SUBJECT

Wiring Repair Procedure for Firing Circuits of Airbag Systems; General Guidelines

SITUATION

Damaged or defective wires and connectors (e.g. chaffed insulation, broken connector pins, torn crimping) in airbag firing circuits, will cause the airbag light (SRS light) to illuminate, and will set fault code "resistance too high" in airbag control module.

CORRECTION

It is acceptable to repair (replace) individual pairs of firing circuit wires by using "Airbag Repair Cable" kits, crimping connectors and insulation shrink tubing. Part numbers for the assortment of "Airbag Repair Cable" kits are listed in the BMW Electronic Parts Catalog (EPC) sections 61 12 19, and 61 12 40. A detailed repair procedure can be found in the BMW Technical Information System (TIS), Repair Instruction RA 72 12 a "Repairing airbag cables".

IMPORTANT:

  1. - Only one crimping connector can be fitted into a single wire of the airbag firing circuit.
  2. - The firing circuit wires cannot be lengthened as a result of the repair.
  3. - Any damage to wires or connectors (for the side airbag firing circuit) in the door wiring harness must be repaired by replacing the entire door wiring harness.

PROCEDURE

CAUTION: When performing diagnosis or repairs to the airbag system, always follow the "Safety Regulations for Handling Components of the Airbag System" (TIS 32 34..).
  1. Diagnose suspected wiring harness. Follow the appropriate test module procedure of DIS/MoDiC.
  2. Expose the affected twisted pair of wires in the wiring harness between the damaged point and the nearest connector. If the connector is at fault, expose the area near the connector. The exposed area should be suitable for installation of the crimping connectors.
    IMPORTANT: Do not install crimping connector in the part of the wiring harness which is subjected to movements, or which carries mechanical load.
  3. The affected wiring harness must be disconnected from both: airbag devise and airbag control module.

    Cut through the affected pair of ignition circuit wires (use appropriate tool e.g. the insulation striper/wire cutter P/N 61 9 043 found in the Electric Repair Kit IV P/N 61 9 020). See Fig 1 .

    IMPORTANT: The cuts must be slightly offset, so the crimping connectors will not be immediately adjacent to each other.
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