BMW X5: Repairing Airbag Cables

IMPORTANT: Only repair those cables which show visible signs of damage. In the event of visible damage, make sure there is only one cable repair in effect after the repair work. If no visible damage can be identified, the entire cable must be replaced. When carrying out repairs to the airbag wiring harness, you must use the spare parts offered in the Electronic Parts Catalogue (EPC).

Safety regulations:

Safety regulations for handling components of airbag system.

Instructions for disconnecting and connecting battery.

Procedure for cable repair

In event of non-visible damage to wiring harness:

Disconnect plug connection on airbag module or on adapter plug. It is absolutely vital to disconnect the contacts in succession as there is a risk of them being mixed up! Cut through one cable after the other at an appropriate position, do not under any circumstances cut through both cables at the same time. Insulate cables remaining in wiring harness with insulating tape. Now disconnect plug connection on airbag control unit. Unpin contacts. Cut through one cable after the other at an appropriate position and insulate with insulating tape, do not under any circumstances cut through both cables at the same time. Pin contacts of repair cable for airbag control unit in control unit plug, assignment of repair cables is relevant. Lay repair cable in car parallel to existing airbag lead.

Now pin in contacts for airbag control unit or contacts of adapter plug, assignment of repair cables is relevant.

Cut off excess length of repair cable in proximity (visible area) of airbag module or of adapter plug. Twist open cables. With the connectors and shrink-fit hoses in the Electronic Parts Catalogue (EPC), reconnect the cables with the same cable colors. Twist cables again, open length (twist) must not exceed 40 mm. Secure interface (shrink-fit hoses) with insulating tape to prevent cables from twisting open.

Instructions for cutting off, insulating, crimping cables, installing and removing contacts:

Cutting off and insulating cables.

Repairing a plug connection using connectors.

Installing and removing contacts.

In event of visible damage:

Expose cable at damaged areas. Cut through one cable after the other at an appropriate position and insulate cables no longer required in wiring harness with insulating tape, do not under any circumstances cut through both cables at the same time. Now, depending on the scope of work, unpin contacts either on airbag control unit/airbag module or on adapter plug. Cut off unpinned cables. Insulate cables remaining in wiring harness with insulating tape. Now pin in contacts of repair cable, assignment of repair cables is relevant. Lay repair lead in car parallel to existing airbag lead up to cutting point. Cut off excess length of repair lead. Twist open cables.

Connect cables with connectors and shrink-fit hoses in Electronic Parts Catalogue (EPC), assignment of repair cables is relevant. Twist cables again, open length (twist) must not exceed 40 mm. Secure interface (shrink-fit hoses) with insulating tape to prevent cables from twisting open.

Instructions for cutting off, insulating, crimping cables, installing and removing contacts:

Cutting off and insulating cables.

Repairing a plug connection using connectors.

Installing and removing contacts.

SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY

Battery acid is highly corrosive:

Do not allow any battery acid to come into contact with the eyes, the skin or clothing. Therefore wear protective clothing, gloves and goggles.

Do not tilt the battery, acid may emerge from the vent opening.

In event of contact with acid:

If acid is splashed into the eyes, rinse them immediately for several minutes with clear water. You must then consult a doctor without delay.

If acid is splashed onto the skin or clothing, neutralize it immediately with a soapy solution and rinse with lots of water.

Seek medical attention immediately if battery acid is accidentally swallowed.

Explosion hazard:

Strictly no flames, sparks, naked light! A highly explosive mixture of electrolytic gas is created when batteries are charged. The rooms where charging is carried out must therefore always be well ventilated.

Avoid the formation of sparks when handling cables, wiring and electrical devices.

Turn the ignition lock to the 0 position before disconnecting or connecting the battery.

Do not place tools or any similar object on the battery (danger of short-circuiting and explosion!).

GENERAL INFORMATION ON INTELLIGENT BATTERY SENSOR (IBS)

WARNING: Danger of destruction in event of mechanical strain

• Do not introduce any additional connections at the battery negative terminal.
• Do not modify the grounding cable.

  The grounding cable also serves to dissipate heat.

• Do not establish any connection between the IBS and the sensor screw.
• Do not use force when disconnecting the pole shoe from the battery terminal:
  • Do not pull on the grounding cable.
  • Do not place any tools under the IBS to lever off the pole shoe.
• Do not use IBS connections as levers.
• Use a torque wrench and set tightening torque in accordance with repair instructions.
• Do not release or tighten down sensor screw (screw with Torx head).
• Avoid contact between IBS and ground.

WARNING: Danger of destruction to IBS and cables when battery is replaced

• The IBS and the cables can be destroyed by mechanical strain when the battery is replaced. Therefore avoid mechanical strain.
• The size (capacity) of the battery required for the car is coded in the Car Access System (CAS).
• Use the battery size (capacity) installed as standard when replacing the battery.
• Register battery change via Service Function (Progman or DIS).
• Delete fault entries in the Digital Engine Electronics (DME) associated with battery replacement.
• Always proceed in accordance with the repair instructions.

NOTE: Battery draining possible in spite of the intelligent battery sensor IBS being fault-free.

• A battery can be drained (e.g. with lights or radio switched on) even when the IBS functions perfectly in conjunction with power management.
• For this reason, only replace the IBS when a corresponding fault is entered in the DME or DDE.

READ NEXT: