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.

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