Notes on handling wiring harnesses and cables

The following applies in general: 

To avoid damage, observe the following instructions:

• Avoid compressive and tensile loads
• To ensure professional repairs, perform repair work only with BMW-approved or recommended special tools and spare parts
• Make sure cables are laid without kinks or abrasions
• Ensure non-contacting routing at sharp-edged body parts; use edge protection if necessary
• Secure additionally laid cables/leads with cable ties

In addition: 

48V cables 

• 48V cables are not to be repaired.
• 48V cables must be replaced in their entirety.

Shielded lines 

In the case of junctions in the shielding, there may be inconsistency in electromagnetic radiation and interference immunity. Consequently, distinctions have to be drawn between the following types:

Coaxial cable 

• Shielded coaxial cables RTK031 may only be repaired with a special crimping tool.
• For antenna wires only the contact bushing may be repaired.
• RG174 Lines and the contact bushing may not be repaired.

CVBS cables 

• CVBS cables may not be repaired.
• CVBS cables must be replaced in their entirety.

HSD lines 

• HSD lines may not be repaired.
• HSD lines must be replaced in their entirety.

Fiber-optic cables: 

Attention! 

• Optical fibers are permitted to show only one  separation point (bridge). Replace optical fibers if necessary
• Smallest permissible bending radius is 25 mm
• Avoid effects of heat ≥ 85°

Working with cables and fiber-optic cables. Refer to CUTTING, STRIP OFF INSULATION AND CRIMPING OPTICAL FIBERS  .

FlexRay (twisted cables): 

It is possible to repair the FlexRay. The cables can be joined together with conventional BUTT CONNECTORS AND HEAT-SHRINK TUBING  in the event of damage.

Airbag lines: 

REPAIRING AIRBAG CABLES .

Ribbon cables: 

Repairing ribbon cables

Replacement of wiring harnesses: 

Repair wiring harnesses mostly cover the full scope of vehicle equipment. If certain optional equipment is not installed in the vehicle, observe the following:

• Fasten any remaining plugs.
• Seal any remaining plugs outside the vehicle interior, e.g. with butyl tape, so that there is permanent protection against moisture ingress.
• If necessary, wrap the plug of the repair wiring harness.

Procedure 

The separation point between the vehicle-side wiring harness and the repair wiring harness is located in the vehicle interior  (in the footwell, for example):

• Cut the additional socket housing and connect the lines to the vehicle-side wiring harness using a butt connector.
• Alternatively, a suitable pin housing can be fitted on the vehicle-side wiring harness and connected to the additional socket housing.

However, this is permitted only if the following conditions are met:

• Carpets must not protrude visibly or become deformed due to the installation of the additional plug connection.
• It must be possible to install the adjacent components (for example, trims, trim panels, etc.) correctly after installing the additional plug connection.
• All the attachment points of the adjacent components (for example, trims, trim panels, etc.) must engage correctly.
• There must be no rattling noise due to the installation of the additional plug connection.
• The additional plug connection must not damage the adjacent components/wiring harnesses, etc..

The separation point between the vehicle-side wiring harness and the repair wiring harness is located outside the vehicle interior  (in the wheel arch, for example):

• Cut the additional socket housing and connect the lines to the vehicle-side wiring harness using a butt connector.
• Using the additional socket housing is not permitted with a separation point outside the vehicle interior  .