12 .. ... Installing Repair Kit For Wiring Harness Section, Throttle Valve Assembly

12 .. ... Installing Repair Kit For Wiring Harness Section, Throttle Valve Assembly (N62TU)







IMPORTANT:
Risk of injury
Risk of injury from soldering iron and hot-air blower and dripping soldering tin.
Temperature greater than 180 °C.

Wear safety goggles and protective gloves.







IMPORTANT: Read and comply with notes on protection against electrostatic discharge (ESD protection) .







Note on ordering:
- Workshop equipment
- Workshop equipment catalogue
- Order no. - 81 24 9 408 476







Necessary preliminary tasks:
- Read out fault memory of DME control unit
- Turn off ignition
- Disconnect battery negative lead
- Remove air intake hose
- E60, E61, E63, E64, E65, E66 only:
Remove acoustic cover
- E70 only:
Remove intake silencer housing







E70 only:
Release screws.
Remove holder (1).

NOTE: For this job item do not remove ignition coil covers (2).







Unlock plug (1) on servomotor on right and disconnect.
Unclip and remove cable duct cover (2).







Unlock plug (1) on throttle valve assembly and disconnect.
Release cable from retainer (2) and feed out.







IMPORTANT: Risk of short circuits

Cables must not all be cut through simultaneously

Release cables from throttle valve assembly from cable duct.

Cut through cables approx. 20 mm after corrugated tubing individually .







Strip insulation on cable ends of engine wiring harness (1).







Cut off repair kit cable (1) at own discretion behind corrugated tubing.







IMPORTANT: Risk of injury and damage

Connect cable of engine wiring harness and repair kit wiring harness as per table to sleeve (1).

In so doing, crimp sleeve (1) with tool (81249408476). Then solder crimped cable ends.

IMPORTANT: Make sure no cables are damaged by the soldering iron.












Pull heat-shrink tube (1) over soldered cable ends.

Bond heat-shrink tubes watertight with hot-air blower.

IMPORTANT: Make sure no cables are damaged by the hot-air blower.







Lay cable ends (1) with stripped insulation into cable duct.
Secure corrugated tubing (2) to cable duct.
Install cable duct cover.







Attach plug (1) to throttle valve assembly.
Clip wiring harness to retainer (2).
Secure wiring harness with cable strap (3).







NOTE:
Check wiring harness routing.
Check plug connections for correct seating.
Assemble engine. Check stored fault messages.
clear fault memory.