61 00... 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

The following additionally applies

Shielded lines

Interference radiation and interference resistance can lead to neutral zones at contact points in the shielding. Consequently, distinctions have to be drawn between the following types:

Coaxial cable

Shielded coaxial cables RTK031 may only be repaired using an appropriate 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:

NOTE: Fiber-optic cables are colored differently as follows:

Green = MOST (M edia O riented S ystem T ransport) optical fiber
Yellow = ISIS (I ntegrated S ervice and I nformation S erver) optical fiber
Orange=repair optical fibers

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 61 13... CRIMPING OPTICAL FIBERS and 61 13... CUTTING, STRIP OFF INSULATION AND CRIMPING OPTICAL FIBERS

FlexRay (twisted cables):

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

NOTE:

FlexRay lines may only reveal one separation point (bride); replace complete line if necessary.
If possible, maintain twisted cable after repair.
After repairs, twist cables as close as possible to the connector/separation point.
Twisting must be as symmetrical as possible.

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.

NOTE: Repair wiring harnesses can be equipped with an additional socket housing (e.g. 30-pin), which was not provided on the previous vehicle-side wiring harness. This bushing housing also cannot be found on the wiring diagram.

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.