Rear Hatch - Various Electrical Problems
Group 61General Electrical Systems
Bulletin Number
61 53 01
Woodcliff Lake, NJ
August 2001
Service Engineering
SUBJECT
Various Electrical Problems Related to Rear Hatch
MODEL
X5
SITUATION
Some X5s manufactured prior to 7/01 may exhibit various intermittent electrical faults related to circuits in the upper rear hatch.
CAUSE
When the wiring harness is routed through an opening in the inner roof panel at the right rear corner of the vehicle, the wires can be chafed by a sharp edge on the panel. The exposed wires can ground out intermittently as the wires move when the vehicle is driven, or as the the rear hatch is opened and closed.
CORRECTION
The stamping of the inner roof panel has been modified to eliminate the sharp edge as of the third week of June, 2001.
Vehicles produced prior to the change may exhibit intermittent faults due to the chafing of the harness which must be repaired.
PROCEDURE
If normal diagnostics indicate a wiring problem in any of the circuits that enter the rear hatch at the upper passenger's side, check the wiring harness for damage.
To access the point where the damage occurs it will be necessary to drop the rear of the headliner and disconnect the harness inside the hatch to gain sufficient slack to pull the harness forward for repair.
Repair any damaged wires in the harness, cover the harness with a section of plastic corrugated conduit, cover the sharp edge of the inner roof panel with duct tape, and reconnect the harness.