Repair Procedure
PROCEDURERepairs can be done with the vehicle on the ground.
1. Open the Retractable Hardtop (RHT) for better access to the work area.
2. Make certain the ignition is off.
3. Move the seat fully forward.
Note:
All photos show the procedure for the driver's side. The tensioner harness for the driver's side has YELLOW twisted wires. The only difference for the passenger's side is that the harness wires are BLUE and GREEN.
4. Remove B-pillar trim. Refer to TIS operation 51 43 120 and 51 43 125.
The photo shows the upper trim piece already removed, along with the storage area net disconnected.
The lower trim piece (arrow) still needs to be removed.
Note:
When removing the top trim piece, there is no need to remove the round plug (circled) from the body. Carefully slip the trim piece over the plug, tilt the trim piece upwards and rearwards, and work it off the plug.
5. Follow airbag safety instructions REP 72 00... for safety precautions when working on airbag modules and the pyrotechnic safety belt tensioners. Improper handling can result in unintended deployment of the belt tensioner, possibly leading to injuries.
6. Access the wiring harness near the safety belt retractor.
Disconnect the plug (arrow) from the vehicle harness going to the retractor.
Note:
The other yellow twisted wire is for the stereo system speaker- do not mix up which harness you cut!
7. Cut off the harness as close to the harness wire upper joint (circled) possible.
Discard the removed connector.
8. Locate the retractor harness in the lower door sill area (circled).
9. There will already be two heat shrink tubes tucked into the wire harness (circled) from a previous repair.
Pull the tubes and the yellow twisted wires out enough to cut them immediately below the shrink tubing (shown with dotted line).
The previously installed repair harness can now be removed.
10. Obtain the yellow harness from the repair kit (P/N 61 12 6 900 928).
Note:
The kit contains 2 sets of twisted wires, 4 crimps, 4 heat shrink tubes. The blue/green harness will be installed on the passenger side.
11. Route the yellow harness from the retractor connector down inside the wiring shields to the area from Step 9.
12. Cut the two repair harness wires slightly below (toward the front of the car) the heatshrink tubing. For more information on repairing airbag cables, refer to REP 61 00... (Repairing airbag cables)
Strip 4 mm (3/32") of insulation from each wire (circled) of the vehicle harness that was cut.
The photo shows the new repair harness (top) with the stripped wires from the vehicle harness.
13. Position one heat-shrink tube from the repair kit over each of the two wires.
Note:
The tubing appears to be very large for the wire. However, if heat is applied sufficiently long to the crimped area, the tubing will shrink firmly over the wire (shown in Step 15).
14. Double crimp (wire crimp and insulation crimp), matching up their colors (yellow/black wire and yellow/brown wire).
Note:
After crimping each wire together, test the integrity of the crimp by gently pulling each end to make sure the crimp connection does not separate.
15. Position the heat-shrink tubes so they are centered over the crimp.
Use a heat gun to fully shrink the tubes.
Note 1:
Sealant will ooze out of each end (arrows) to indicate full shrinkage. This feature is an additional protection for durability.
Note 2:
Let the tubing cool down for several minutes before handling.
16. Position both wires back within the vehicle harness (circled).
17. Fasten the repair harness to the vehicle harness (arrow and line) using BMW harness tape.
Route the repair harness behind the vehicle harness (circled) to prevent movement.
18. Reassemble the vehicle.
Note 1:
The M12 bolt that fastens the safety belt swivel guide to the body (arrow) must be reused, but cleaned off for thread sealant.
Clean the threads of old sealant using a wire brush and brake cleaner spray.
Apply Loctite 243 threadlocker (blue-colored) to threads.
Torque to 90 Nm.
Note 2:
When installing the upper trim panel, start by fastening the panel onto the rearmost plug (arrow).
19. Perform steps 3 through 18 on the belt tensioner harness for the other seat (the passenger seat utilizes the BLUE/GREEN harness).
20. Close the RHT.
21. Obtain the campaign label SD#92-366, emboss your BMW center warranty number in the middle of the label and punch out code number 548 printed on the label; and affix the label to the B-pillar, as shown.