General Electrical System - Repair

• Safety And General Information
  • 00 Safety information for working on vehicles with automatic engine start-stop function (MSA)
    • Notes
    • Observe safety precautions when working on MSA vehicles
      • Notes
      • MSA function is deactivated by
      • When working with diagnosis tools
  • 6100... Safety instructions for handling vehicle battery
    • Battery acid is highly corrosive
      • Notes
      • In event of contact with acid
      • Explosion hazard
  • 6100... Battery
    • Notes
    • Battery care and maintenance
    • Battery test
  • 6120... Battery replacement information
    • Notes
    • Vehicles with energy management systems (IBS, power module): Register battery replacement
  • 6100... Diagnosis for Condition Based Service
    • Notes
    • 4 service functions are available in the BMW diagnosis system for maintenance
    • Service Function: Transport Mode/Pre-delivery check
    • Service Function: CBS Correction Tester Data
    • Service Function: Reset CBS Condition Based Service
    • Service Function: CBS vehicle data correction
  • 6112... General information on intelligent battery sensor (IBS)
  • 6100... Notes on handling optical fibres
  • 6100... Notes on handling wiring harnesses and cables
    • The following applies in general
    • The following additionally applies
  • 1200... Notes/information on start assistance (jump starting)
    • Notes
    • Preparation
    • Operation
    • Risk of explosion!
  • 6120908 Performing battery "power reset" (for programming/coding control unit(s))
    • Notes
    • The following steps must be carried out for a "power reset"
  • 6100... Repairing airbag cables
    • Notes
    • Safety regulations
    • Procedure for cable repair
      • In event of non-visible damage to wiring harness
      • In event of visible damage
  • 6113... Treating cables and fibre-optic cables
    • Special tools required
    • Subject of repair instructions
  • 6113... Unlocking and disconnecting different plug connections
• Wiring Harness
  • 6100... Notes on handling wiring harnesses and cables
    • The following applies in general
    • The following additionally applies
• Auxiliary Cable
  • 6112... General information on intelligent battery sensor (IBS)
  • 6112013 Replacing battery negative lead
    • Notes
    • Necessary preliminary tasks
    • Vehicles up to 12/2006 with IBS
  • 6112002 Replacing battery positive lead (from battery to luggage compartment connector)
    • Notes
    • Necessary preliminary tasks
    • Replacement with build date up to 03/2006
  • 6112004 Replacing battery positive lead (from luggage compartment connector to engine bulkhead connector)
    • Notes
    • Necessary preliminary tasks
  • 6112200 Replacing wiring harness in left or right front door
    • Necessary preliminary tasks
  • 6112210 Replacing wiring harness in left or right rear door
    • Necessary preliminary tasks
  • 6113... Unlocking and disconnecting different plug connections
• Plug Connection, Terminal, Fuse Box
  • 6113... Opening plug housings and removing contacts of different plug systems
    • Notes
    • 6113... In-line plugs, 24-pin, Hybrid System MQS/MPQ
      • Manufactured by AMP
    • 6113... In-line plugs, 30-pin, Hybrid System MQS/MPQ
      • Manufactured by AMP
    • 6113... In-line plugs, 6- to 50-pin, System Elo
    • 6113... Inline plugs, 6-, 8-pin, System MQS
    • 6113... Plug housing, LCC contact (load current contact)
      • Notes
    • 6113... Socket housing (radio plug), Hybrid System MQS/MPQ
      • Manufactured by AMP: The following contact types without strand sealing can be fitted in the plug housings
      • Removing MPQ contacts from radio plug
      • Removing MQS contacts from contact carrier
      • Removing MPQ contacts from contact carrier
    • 6113... Socket housing 42-, 43-pin, Hybrid System MQS/MPQ
      • Manufactured by AMP: The following contact types without strand sealing can be fitted in the socket housings
    • 6113... Socket housings, 2x21-, 2x27-pin, Hybrid Systems MQS/MPQ, Elo/Elo-Power
      • Manufactured by AMP: The following contact types without strand sealing can be fitted in the socket housings
      • Manufactured by Siemens: The following contact types without strand sealing can be fitted in the socket housings
  • 6113... Butt connector for repairing a plug connection
    • Notes
  • 6113... Crimping Micro Power Quadlock contacts (MPQ)
    • Notes
  • 6113... Crimping Micro Quadlock System contacts (MQS)
    • Notes
  • 6113... Crimping annular contacts
    • Special tools required
      • Crimping annular contacts
  • 6113... Crimping optical fibres
    • Notes
  • 6113... Crimping stop parts
    • Special tools required
      • Spare parts for in-car electronics (housing and contacts)
        • Crimping contact sleeves for 4 mm2 fan connectors and ignition cable contacts
        • Checking crimping
  • 6113... Cutting off, stripping insulation and cutting optical fibres to length
    • Special tools required
      • Notes
      • Cutting optical fibre
      • Stripping insulation from optical fibre
      • Cutting optical fibre to length
  • 6113... Cutting to length and stripping insulation from cables
  • 6113... Fuse holder
  • 6113... Installing fan connector for retrofitting/repairs
    • Special tools required
    • Installation in wet area (engine compartment, wheel arch)
    • Installation in dry area (interior, luggage compartment)
  • 6113... Main relay connector for DME
  • 6100... Notes on handling optical fibres
  • 6100... Notes on handling wiring harnesses and cables
    • The following applies in general
    • The following additionally applies
  • 6113... Relay carrier
  • 6113050 Removing and installing or replacing fuse box in passenger compartment (built after 03/2007)
    • Notes
    • Necessary preliminary tasks
  • 6113... Removing and installing/replacing OBD-II socket
    • Notes
      • Necessary preliminary tasks
  • 6131134 Removing and installing/replacing USB/audio interface connecting socket
  • 6100... Repairing airbag cables
    • Notes
    • Safety regulations
      • Notes
      • Procedure for cable repair
        • In event of non-visible damage to wiring harness
        • In event of visible damage
  • 6113... Repairing airbag leads (build date/version affected 04/2008 to 07/2008)
    • Notes
  • 6113... Repairing ribbon cables
    • Notes
  • 6135502 Replacing the trailer module (09/2006-03/2009)
    • Notes
    • Necessary preliminary tasks
    • Special tools for disconnecting
    • Special tool for crimping
  • 6113... Socket of flat-type connector housings
  • 6113... Special tools for wiring harness repairs
    • Special tools required
      • Release and press-out tool
      • Cutting to length and stripping insulation from cables
      • Crimping stop parts (small contacts)
      • Crimping stop parts (large contacts)
      • Crimping antenna elbow plugs
      • Repair kit for ignition cables and for crimping fan connector receptacles 4 mm 2
      • Repairing ribbon cables
  • 6113... Treating cables and fibre-optic cables
    • Special tools required
      • Notes
      • Subject of repair instructions
  • 6113... Unlocking and disconnecting different plug connections
• Distribution Box, Power Support Points
  • 6114010 Removing and installing/replacing distribution box (on battery)
    • Notes
    • Necessary preliminary tasks
  • 6114... Removing and installing/replacing engine compartment B+ terminal
    • Notes
    • Necessary preliminary tasks
• Battery
  • 6120... AGM battery
    • Notes
    • Introduction
    • Service life of AGM batteries
    • Brief component description
    • Notes for Service department
  • 6100... Battery
    • Notes
    • Battery care and maintenance
    • Battery test
  • 6120... Battery charge
  • 6120... Battery open-circuit current test
  • 6120... Battery replacement information
    • Notes
    • Vehicles with energy management systems (IBS, power module): Register battery replacement
  • 6120900 Disconnecting and connecting battery negative lead
    • Notes
    • Necessary preliminary tasks
  • 6112... General information on intelligent battery sensor (IBS)
  • 1200... Instructions for disconnecting and connecting battery
    • Notes
    • Before disconnecting battery
    • General notes on disconnecting battery
    • After connecting battery
    • Vehicles with a two - battery system
  • 1200... Notes/information on start assistance (jump starting)
    • Notes
    • Preparation
    • Operation
    • Risk of explosion!
  • 6120908 Performing battery "power reset" (for programming/coding control unit(s))
    • Notes
    • The following steps must be carried out for a "power reset"
  • 6100... Repairing airbag cables
    • Notes
    • Safety regulations
      • Notes
      • Procedure for cable repair
        • In event of non-visible damage to wiring harness
        • In event of visible damage
  • 6100... Safety instructions for handling vehicle battery
    • Battery acid is highly corrosive
      • Notes
      • In event of contact with acid
    • Explosion hazard
  • 6120... Threshold values for battery inspection of all battery (telephone except for telephone battery)
• Battery/Vapor Separator
  • 6120900 Disconnecting and connecting battery negative lead
    • Notes
    • Necessary preliminary tasks
  • 6120908 Performing battery "power reset" (for programming/coding control unit(s))
    • Notes
    • The following steps must be carried out for a "power reset"
  • 6121010 Removing and installing or replacing battery
    • Notes
    • Necessary preliminary tasks
• Switches, Horn, Small Devices
  • 6142... Removing and installing/replacing DC/DC converter
• Switches
  • 6131996 Carrying out steering angle sensor adjustment
  • 6131... Overview of switches
  • 6131195 Removing and installing (replacing) front controller (from 09/2008)
    • Notes
    • Necessary preliminary tasks
  • 6Foto131038 Removing and installing (replacing) switch for passenger airbag deactivation
    • Notes
    • Necessary preliminary tasks
  • 6131122 Removing and installing/replacing tow hitch switch
    • Necessary preliminary tasks
  • 6131043 Removing and installing or replacing roof switch cluster
    • Notes
  • 6131133 Removing and installing/replacing AV connection socket
  • 6131023 Removing and installing/replacing Start/Stop switch
    • Necessary preliminary tasks
  • 6131134 Removing and installing/replacing USB/audio interface connecting socket
  • 6131241 Removing and installing/replacing bonnet/hood contact switch
  • 6131221 Removing and installing/replacing both multifunction steering wheel switches
    • Necessary preliminary tasks
  • 6131113 Removing and installing/replacing both shift paddles for automatic transmission
    • Necessary preliminary tasks
  • 6131229 Removing and installing/replacing both switches on sport steering wheel
    • Necessary preliminary tasks
  • 6131054 Removing and installing/replacing Center console control panel (with CCC/ASK, CIC)
    • Notes
    • Necessary preliminary work
  • 6131052 Removing and installing/replacing Center console switch cluster (without CCC/ASK)
    • Notes
  • 6131006 Removing and installing/replacing fixture for steering column stalk
    • Notes
    • Necessary preliminary tasks
  • 6131037 Removing and installing/replacing light control unit
    • Notes
  • 6131008 Removing and installing/replacing steering-column switch cluster
    • Notes
    • Necessary preliminary work
  • 6131101 Removing and installing/replacing switch for backrest width adjustment
    • Necessary preliminary tasks
  • 6131079 Removing and installing/replacing switch for hazard warning flashers/central locking
    • Necessary preliminary tasks
  • 6131208 Removing and installing/replacing switch for lumbar support
    • Necessary preliminary tasks
  • 6131083 Removing and installing/replacing switch for unlocking rear lid
  • 6131011 Removing and installing/replacing volute spring cassette
    • Notes
    • Necessary preliminary tasks
  • 6131009 Repairing steering column switch cluster (SZL)
    • Notes
    • Necessary preliminary tasks
    • Removal
    • Installation
  • 6131310 Replacing brake light switch
    • Necessary preliminary tasks
  • 6131382 Replacing coolant level switch
    • Notes
    • Necessary preliminary tasks
  • 6131492 Replacing level switch for windscreen washer system
    • Necessary preliminary tasks
  • 6131115 Replacing rocker switch for side window operation (front)
    • Notes
  • 6131116 Replacing rocker switch for side window operation (rear)
    • Notes
  • 6131204 Replacing switch combination for seat adjustment
    • Necessary preliminary tasks
  • 6131255 Replacing switch for door mirror
• Horn
  • 6133050 Removing and installing/replacing left fanfare horn
  • 6133055 Removing and installing/replacing right fanfare horn
    • Necessary preliminary tasks
• Control Units, Modules
  • 6135679 Initializing rain/light (solar) sensor
  • 6135... Notes on ESD protection (Electro Static Discharge)
    • Notes
  • 6135... Overview of control units
  • 8410050 Removing and installing (replacing) USB hub
    • Notes
    • Necessary preliminary tasks
  • 6135015 Removing and installing (replacing) control unit for Car Access System
    • Notes
    • Necessary preliminary tasks
  • 6135950 Removing and installing (replacing) control unit for comfort access system
    • Notes
    • Necessary preliminary tasks
  • 6135080 Removing and installing (replacing) control unit for left or right seat adjustment (front seat)
  • 8421542 Removing and installing (replacing) hands-free charging electronics (High)
    • Notes
    • Necessary preliminary tasks
  • 6135177 Removing and installing (replacing) rain/light sensor
    • Notes
    • Necessary preliminary tasks
  • 6135107 Removing and installing or replacing Junction Box electronics
    • Notes
    • Necessary preliminary tasks
  • 6135001 Removing and installing trailer module
    • Notes
    • Necessary preliminary tasks
  • 6135975 Removing and installing/replacing bumper antenna for Comfort Access System
    • Necessary preliminary tasks
  • 3243010 Removing and installing/replacing control unit for active front steering
    • Notes
    • Necessary preliminary tasks
    • After installation
  • 6135095 Removing and installing/replacing control unit/module for seat heating
  • 6135115 Removing and installing/replacing footwell module
    • Notes
    • Necessary preliminary tasks
  • 6135953 Removing and installing/replacing interior antenna for comfort access system
  • 6135954 Removing and installing/replacing interior antenna for comfort access system (rear)
    • Notes
  • 6135970 Removing and installing/replacing rear luggage compartment antenna for comfort access system
    • Necessary preliminary tasks
  • 6411970 Replacing fogging sensor
    • Notes
  • 6135502 Replacing the trailer module (09/2006-03/2009)
    • Notes
    • Necessary preliminary tasks
    • Special tools for disconnecting
    • Special tool for crimping
  • Vehicle programming and encoding
• Relay
  • 6113... Main relay connector for DME
  • 6113... Relay carrier
• Windscreen Wipers
  • 6161... Adjusting left or right windscreen wiper
    • Notes
  • 6161010 Checking/adjusting contact angle of windscreen wiper arms on windscreen
    • Notes
  • 6161... Overview of windscreen wiper and washer system
  • 6161100 Removing and installing/replacing both windscreen wiper arms
    • Notes
  • 6161270 Removing and installing/replacing bracket for windscreen wiper system complete with motor
    • Necessary preliminary tasks
  • 6161041 Replacing both windscreen wiper blades
• Headlight Washer System
  • 6161... Overview of windscreen wiper and washer system
  • 6167083 Removing and installing/replacing left or right high-pressure nozzle of headlight washer system
    • Notes
  • 6167010 Removing and installing/replacing washer pump of headlight washer system
    • Necessary preliminary tasks
• Window Washer System
  • 6161... Overview of windscreen wiper and washer system
  • 6171015 Removing and installing/replacing a spray nozzle in windscreen washer system
    • Notes
    • Necessary preliminary tasks
  • 6171100 Removing and installing/replacing windscreen washer pump
    • Necessary preliminary tasks
  • 6171061 Replacing washer fluid reservoir for windscreen washer system
    • Necessary preliminary work