BMW X5: Starter Lead

REMOVING AND INSTALLING OR REPLACING BATTERY POSITIVE LEAD (BETWEEN STARTER, ALTERNATOR AND BATTERY POSITIVE TERMINAL)

Necessary preliminary tasks:

• Read out fault memory of DME control unit; if necessary, work through test schedules.
• Switch off ignition.
• Disconnect battery negative lead.
• Remove intake air manifold.

Open cover.

Release nut, remove battery positive lead (1) from battery positive terminal.

Tightening torque.

Release nut and remove battery positive lead (1) from alternator.

Unlock plug (1) and remove.

Unfasten nut.

Tightening torque 12 41 3AZ.

Detach battery positive lead (2) from starter motor and remove.

NOTE: Check stored fault messages. Now clear the fault memory.

Fig. 48: Identifying Cover

REPLACING SAFETY BATTERY TERMINAL (SBK)

CAUTION: Observe safety regulations.

Investigate cause of triggering of safety battery terminal.

To do so, read out fault memory of airbag control unit. Note fault messages stored in memory. Rectify faults. Then clear fault memory.

Use of safety battery terminal:

• From model year 1998 in Series E38, E39, E46
• From 4/99 in E36/Z3
• in each of following new Series

The different models have different installation locations:

Battery in engine compartment

Safety battery terminal is replaced with cable up to battery positive support point.

Safety battery terminal is omitted as from 03/2002 from all E46 LHD models with 4-cylinder engines.

Battery in luggage compartment behind side trim panel

Remove side trim panel.

Follow instructions for disconnecting and connecting battery.

Disconnect and cover battery negative lead.

Fig. 49: Removing Side Trim Panel

Release front side trim panel partly and fold forward.

Fig. 50: Releasing Front Side Trim Panel

Battery in luggage compartment under floor trim panel

Follow instructions for disconnecting and connecting battery.

Fold back floor trim panel (1).

Lift cover (2) on battery negative lead.

Disconnect and cover battery negative lead (3).

Release nuts (4).

Remove battery cover.

Fig. 51: Lifting Cover On Battery Negative Lead

Battery in luggage compartment under spare wheel

Remove spare wheel.

Release screws.

CAUTION: Do not kink air pipes.

Set air supply system (1) to one side.

Follow instructions for disconnecting and connecting battery.

Disconnect battery negative lead.

Fig. 52: Locating Spare Wheel Screws

Disconnect supply cable (1) for vehicle electrical system.

Installation:

Remove faulty fuses and carry out troubleshooting.

Fig. 53: Identifying Supply Cable

CAUTION: Pay attention to interface.

Find matching interface (e.g. approx. 10 cm behind rear seat backrest in E46 touring).

Lay repair cable parallel to battery positive lead.

Mark interface of battery positive lead at end of repair cable.

Fig. 54: Locating Mark Interface Of Battery Positive Lead

Release cable ties (1).

Disconnect plug connection (2).

Fig. 55: Identifying Plug Connection And Cable Ties

CAUTION: Do not use bolt cutters or similar tools to cut through the cable.

A cable end that has been squashed flat will no longer fit into the clamping sleeve.

Saw through battery positive cable at marked point with an iron saw.

Fig. 56: Locating Battery Cable

Strip insulation - length (A) - from cable end.

Distance (A) = 15 mm.

Fig. 57: Identifying Strip Insulation - Length

Push heavy-current connector (1) over stripped cable end and screw into position.

Fig. 58: Identifying Heavy-Current Connector

Push shrink-fit hose (3) over repair cable.

Screw threaded sleeve (1) of repair cable (2) to heavy-current connector.

Fig. 59: Identifying Shrink-Fit Hose And Threaded Sleeve

Push shrink-fit hose (1) over connecting point and shrink on with a hot-air blower (2).

Fig. 60: Pushing Shrink-Fit Hose

NOTE: Heat up shrink-fit hose until it has settled completely around the connection point.

Fig. 61: Locating Shrink-Fit Hose

When laying the repaired battery positive cable, observe the following:

• The shrink-fit hose must not be scuffed during any movement.
• The repair cable must not cause any disturbing noises during driving operation.

NOTE: Offsetting cutting line by approx. 10 cm produces excess length of battery positive lead (1).

(Shown on E46 touring.)

Fig. 62: Identifying Excess Length Of Battery Positive Lead

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