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

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

TECHNICAL SERVICE BULLETIN

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

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.
   Fig 1: Cutting Ignition Circuit Wire

   
4. Strip off insulation at the end of the wires (stripped length 4.5 mm). See Fig 2 .
   Fig 2: Stripping Wire Insulation

   
5. Select the appropriate (for particular application) "Airbag Repair Cable" kit (part numbers can be found the EPC sections: 61 12 19 and 61 12 40). See Fig 3 .
   Fig 3: Airbag Repair Cable Kit

   
6. Shorten the wires from the "Repair Cable" kit to the same length as the removed defective wires.
   IMPORTANT: Do not extend the length of the repaired harness. If necessary, shorten the repaired wires.
7. Insert shrink tubing (P/N 61 13 1 379 833) on both repaired wires of the firing circuit. See Fig 4 .
   Fig 4: Installing Shrink Tubing On Wire

   
8. Connect the wires of the existing firing circuit to the wires from the "Airbag Repair Cable" kit with two crimping connectors (P/N 61 13 8 353 746). See Fig 5 . Use the appropriate crimping tool e.g. pliers with die block P/N 61 9 041 found in the Electric Repair Kit IV P/N 61 9 020.
   Fig 5: Installing Crimp Connector

   
   IMPORTANT: Pin assignment of the repair leads is not relevant.
9. Using a heat gun, shrink the insulation tubing on both sides of the crimping connector. See Fig 6 .
   IMPORTANT: Use caution, do not burn shrink tubing or harness insulation.
   Fig 6: Shrink Tubing On Crimp Connector

   
10. Route the repaired firing circuit harness along the original wiring route and remove the defective (original) pair of wires. Reshape the wiring harness to its original form and attach any protection fittings.
    IMPORTANT: Some of the "Airbag Repair Cable" kits do not include connector housings. In that case the original connector housing (from the removed wiring) must be reused.
11. Reconnect the firing circuit harness to the airbag devise and airbag control module, connect battery and clear all fault codes from the SRS Control Module memory.

PARTS INFORMATION

Part Number	Description	Qty.
61 12 8 386 369	Airbag Repair Cable	1
61 12 8 386 367	Airbag Repair Cable	1
61 12 8 386 370	Airbag Repair Cable	1
61 12 8 386 330	Airbag Repair Cable	1
61 12 8 386 365	Airbag Repair Cable	1
61 12 8 386 368	Airbag Repair Cable	1
61 12 8 386 385	Airbag Repair Cable	1
61 13 8 353 746	Crimping connector	2
61 13 1 379 833	Insulation Shrink-tube	2

WARRANTY INFORMATION

For information only.