General Electrical System - Repair - e90 BMW M3 E90

61 00... Battery

Note. Important notes and instructions for handling batteries in the dealership can be found in: DISCONNECTING BATTERY BATTERY CHARGING EXTERNAL JUMP-STARTING AID

Battery care and maintenance

In low-maintenance batteries, check the acid level at least once a year. If necessary, top up with distilled water up to the top marking.

The increasing number of electronic control units in the car reduces the self-discharging time of the battery (even in standby mode). To maintain the battery service life and to avoid exhaustive discharging, recharge laid-up vehicles every 6 weeks at the latest. The time for self-discharging depends on vehicle type and equipment specification.

Battery test

The battery acid density can be used to measure the charge state. However this test produces uncertainty caused by a design-related range of variation. The acid density e.g. for a charged battery is 1.28 kg/l (in the tropical version the acid density is 1.23 kg/l).

Another interference factor is the acid lamination immediately after filling with distilled water.

Battery wear with partially sulfated and/or heavily contaminated plates will also lead to incorrect acid density test results.

61 20... Battery replacement information

A vehicle battery is constructed for the installation location and the individual power requirements of the particular vehicle. These individual power requirements depend on the motorization and different types of optional equipment. The individually assigned vehicle battery is the ideal compromise between the power requirements of the vehicle electrical system and the weight and service life of the vehicle battery.

Vehicles with the automatic engine start-stop function or particular motorization and optional equipment are equipped with a special vehicle battery (AGM battery), since only this battery type can provide elevated power requirements over the extended service life. Installing a different vehicle battery can cause problems with vehicle electronics, can reduce functions or can cause leakage of battery acid.

In the event of an accident where the airbags are deployed in vehicles with a vehicle battery in the luggage compartment, the electrical connection between the vehicle battery and the trigger is automatically disconnected through pyrotechnics. This prevents a possible short circuit.

Proper operation of all of these safety and convenience functions requires a battery that conforms with specifications and that is properly registered in vehicles with energy management systems (IBS, power module).

Vehicles with energy management systems (IBS, power module): Register battery replacement

The vehicle electrical system is informed about the vehicle battery characteristic data, such as type, size, age and current power capacity. Therefore, only one work scope will be provided that is permitted by the current status of information.

When installing a new vehicle battery, the battery must be registered and thus must also be registered with the vehicle electrical system.

Diagnosis system

Register battery replacement

1. Service functions
2. Body
3. Voltage supply
4. Register battery replacement
5. Test plan

When retrofitting, a more powerful battery may be used. Standard batteries may always be replaced by AGM batteries with the same specifications.

When installing a battery of a different size or a different battery type, this change in vehicle data must be programmed into the vehicle data in accordance with specifications.

Programming system

1. Battery retrofitting

61 00... Diagnosis for Condition Based Service

Note. Red symbol for pre-delivery check

The vehicle is coded at the end of the assembly line so that the red symbol for the pre-delivery check is shown in the Next Service display (same symbol as vehicle check).

The symbol is a reminder to the Service staff that the pre-delivery check has not yet been carried out on this car.

Note. Do not carry out a reset.

Do not confuse this function with the "Vehicle check" scope of maintenance work. Do not perform a reset via the instrument panel.

When performing the pre-delivery check with the service function "Transport mode/pre-delivery check": The symbol is suppressed automatically after carrying out the service function.

Scheme 1186

Scheme 1187

CBS DESCRIPTION CHART

4 service functions are available in the BMW diagnosis system for maintenance

1. Transport mode/pre-delivery check
2. CBS correction, tester data
3. Reset CBS
4. CBS correction of vehicle data

Service Function: Transport Mode/Pre-delivery check

In order to ensure that a vehicle can be handed over to the customer in proper condition, the "Transport mode/predelivery check" service function must be performed.

The following items are checked during the pre-delivery check

1. Deactivation of the transport mode.
2. To determine the vehicle-specific distance travelled per week an adaptation process is activated. Transport and standing times before delivery of the vehicle to the customer therefore do not have any effect on the customer-specific weekly distance travelled. The weekly mileage/kilometrage is used to control escalation from "green" to "yellow" (approx. 4 weeks before "red") for maintenance scopes with remaining distances. It is the distance travelled determined over the last 6 weeks which is taken into account.
3. Encoding or deletion of the legally-specified intervals for the legally stipulated vehicle inspection and emissions test.
4. Inputting the target dates for the legally stipulated vehicle inspection and emissions test (automatically or manually). Automatically: By entering the date of the first registration and the interval Manually: by directly entering the target date
5. Information on initializing the Tele Service depending on the equipment installed on the vehicle.
6. Checking and where necessary adjusting the on-board data for the vehicle.
7. Entry of the date of the first registration of the vehicle.
8. Delete fault memory.

Note. Reduction of input effort. In order to minimize the input effort for the workshop, standardized data is saved on the BMW diagnosis system (for repeat use). The standardized data can be changed with the "CBS Correction Tester Data" service function. Service Function: CBS Correction Tester Data During the service function "Pre-delivery check", the data is automatically stored in the vehicle. With the service function "CBS correction, tester data", standardized data can be changed. The following standardized data can be modified

1. Phone numbers: BMW Group Mobile Service BMW Hotline Home dealer The country-specific phone numbers are contained in the BMW diagnosis system as information text (to be read off when required for input). The phone numbers must be input with the international dialling code.
2. Legally stipulated vehicle inspection (country-specific): Encoding or deletion Interval for calculating the target date The target date is calculated on the basis of the date of the first registration.
3. Legally stipulated emissions test (country-specific): Encoding or deletion Interval for calculating the target date The target date is calculated on the basis of the date of the first registration.

Note. Automation after installation of the BMW diagnosis system.

If the pre-delivery inspection is being carried out for the first time, the standardized data will be defined automatically. It is therefore not necessary to enter the data separately.

Service Function: Reset CBS Condition Based Service

A maintenance scope can be reset with the "Reset CBS Condition Based Service" service function. Even if availability is above 80 %. The reset via the BMW diagnosis system has the advantage that the on-board date is corrected

automatically. The individual maintenance scopes are displayed in the BMW diagnosis system with service counter and availability.

1. The service counter is increased by one count on resetting. In new vehicles all service counters are set to "1". The service counters are used in the Service Acceptance Module (SAM) to control the additional work for specific maintenance operations.
2. On resetting the availability is set at 100%. The percentage availability is the wear reading for the maintenance operation. The greater the availability, the further away the next service. 0% means that the maintenance operation must be carried out.

Service Function: CBS vehicle data correction

After carrying out this service function, it will no longer be possible to restore the previous status.

The service function "CBS vehicle data correction" is available if resetting has been carried out unintentionally. Thus the availability of a maintenance operation can be corrected to a value which corresponds more closely to the actual situation.

For this correction a date or kilometer reading is entered. This data is processed internally to give a percentage availability.

Here, the BMW diagnosis system will only accept a value which is lower that the current status in the control unit. In addition, the service counter of the scope is automatically reduced by one counter.

The entries in the service booklet are used to determine the actual availability. The most recent maintenance measure (kilometer reading and date) allows the reconstruction availability for the specific scope that corresponds more closely to the actual situation. This excludes the correction of availability for brake pads. The residual values for the brake pads must be measured and input (in millimeters).

Note. Reference for distance- and time-dependent maintenance scopes

On correction the availability depends on the distance-dependent and time-dependent calculation.

61 12... General information on intelligent battery sensor (IBS)

Note. Do not connect the charger to the 12 V charging socket

The 12 V charging socket is supplied with voltage by the rear distribution box via relay. This relay drops out after terminal 15 OFF. This means that a trickle charger connected at the 12 V charging socket will be disconnected from the battery. Only charge the battery via the jump start terminal point. Only then can the voltage supply be registered by the vehicle.

1. Do not introduce any additional connections at the battery negative terminal.
2. Do not modify the grounding cable. The grounding cable also serves to dissipate heat.
3. Do not establish any connection between the IBS and the sensor screw.
4. 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.
5. Do not use IBS connections as levers.
6. Use a torque wrench and set tightening torque in accordance with repair instructions.
7. Do not release or tighten down sensor screw (screw with Torx head).
8. Avoid contact between IBS and ground.

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

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

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

61 00... Notes on handling optical fibres

Note. The optical fibres are colored differently as follows: Green = MOST ( M edia O riented S ystems T ransport) optical fibre Yellow = ISIS ( I ntelligent S afety and I ntegration S ystem) fibre-optic cable Orange=repair fibre-optic cables

Follow instructions for PROCESSING CABLES AND OPTICAL FIBRES .

61 00... Notes on handling wiring harnesses and cables

The following applies in general

To avoid damage, observe the following instructions

1. Avoid compressive and tensile loads
2. Make sure cables are laid without kinks or abrasions
3. Ensure non-contacting routing at sharp-edged body components; use edge protection if necessary
4. Secure additionally laid cables/lines with cable straps

The following additionally applies

Shielded lines

Contact points in the shield can cause problems with regard to noise radiation and interference immunity. Consequently, distinctions have to be drawn between the following types

Coaxial line

1. Shielded RTK031 coaxial lines may only be repaired with special crimping tool.

CVBS lines

1. CVBS lines may not be repaired.
2. CVBS lines must be replaced in their entirety.

HSD lines

1. HSD lines may not be repaired.
2. HSD lines must be replaced in their entirety.

Optical fibre cable

Note. Optical fibre cables are colored differently as follows: Green = MOST ( M edia O riented S ystems T ransport) optical fibre Yellow = ISIS ( I ntelligent S afety I ntegration S ystem) optical fibre Orange = repair optical fibre cables

TREATING CABLES AND OPTICAL FIBRE CABLES

FlexRay

It is possible to repair the FlexRay. In the event of damage, the cables can be joined with conventional BUTT CONNECTORS .

Note. The line is a twisted cable. If possible, maintain twist in line after repair.

Airbag lines

REPAIRING AIRBAG CABLES

Ribbon cables

REPAIRING RIBBON CABLES Z

12 00... Notes/information on start assistance (jump starting)

Do not start the engine with help of starting sprays.

Preparation

Conform with the following when starting the engine with a jump starting cable.

1. Ensure that the jump starting cable wires are of appropriate cross-section size.
2. Only use fuse-protected jump starting cables.
3. Check whether the current-supplying battery has 12 V voltage.
4. If the engine is started from the battery of another vehicle, ensure that there is no contact between the bodies of both vehicles.

If the battery in the vehicle supplying power is weak, start the engine of this vehicle and let it run at idling speed.

Operation

It is essential to conform to the procedures so as to avoid injury to persons or damage to parts.

1. Automatic transmission: select drive position "P", apply parking brake.
2. Manual transmission: move gear lever to neutral position, apply parking brake.
3. Ensure that the jump leads cannot get caught in rotating parts, e.g. fan.
4. First connect both positive poles of the batteries with one jump starting cable (red).
5. Use the battery positive terminal in the engine compartment for vehicles with the battery in the luggage compartment.
6. Then use the second jump starting cable (black) to connect the negative post of the current-supplying battery with the earth/ground point (not the negative pole or the body) of the vehicle to be started.

Risk of explosion!

After the engine of the vehicle to be started has fired, first disconnect the jump starting cable between the negative pole and the earth/ground point. Then remove the starting cable from the positive poles.

61 13... Opening plug housings and removing contacts of different plug systems

SPECIAL TOOLS REFERENCE CHART

Ultrasonic-welded connectors (1) can be identified by the welds (2) on their longitudinal side.

Scheme 1188

Note. Special tools referred to in the repair instructions below are contained in the following special tool kits: Release and press-out tool 61 1 150 is replaced from 09/2005 by 61 0 300 (BMW) and 61 0 400 (MINI) Release and press-out tool 61 1 100 (engine)

Repair instructions for opening plug housings and removing contacts of different plug systems

61 20 908 Performing battery "power reset" (for programming/coding control unit(s))

The following steps must be carried out for a "power reset"

1. Switch off and disconnect battery charger
2. Switch off ignition Cars with ignition key: Turn ignition key to 0 position Cars with identification sensor: Remove identification sensor from slot Cars with comfort access system: Make sure terminal is in 0 position
3. Disconnect battery negative terminal
4. Reconnect battery negative terminal (to ensure bus activity)
5. Waiting time (5-10 seconds)
6. Disconnect battery negative terminal
7. Waiting time (1 minute)
8. Connect battery negative terminal and tighten.
9. Connect and switch on battery charger
10. Switch ignition on

61 00... Repairing airbag cables

Safety regulations

Safety regulations for See Recommended Engine Oils For BMW Group Engines See 6100... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY ; BATTERY WITH TERMINAL or SAFETY REGULATIONS FOR HANDLING COMPONENTS WITH GAS GENERATORS .

INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .

Procedure for cable repair

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 .

00 Safety information for working on vehicles with automatic engine start-stop function (MSA)

Observe safety precautions when working on MSA vehicles

Before carrying out practical work on the engine, always ensure that the MSA functionality is deactivated so as to prevent automatic engine starting while work is being carried out in the engine compartment.

MSA function is deactivated by

1. Deactivate MSA by means of button (1) in passenger compartment
2. Open seat belt buckle and driver's door
3. Open engine bonnet/hood and ensure that engine hood/bonnet contact is not in workshop mode

1. Workshop mode
2. Basic setting (engine hood/bonnet open)

B = 7 mm

To make sure that the engine hood/bonnet contact is at the basic setting, if necessary press the hood/bonnet contact up to the limit position before starting work and slowly release.

Scheme 1189

When working with diagnosis tools

1. Observe instructions in diagnosis tool

61 00... 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 or smoking!

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!).

61 13... Treating cables and fibre-optic cables

Note. Special tools referred to in the repair instructions below are contained in the following special tool kits

SPECIAL TOOLS REFERENCE CHART

Subject of repair instructions

1. «SPECIAL TOOLS FOR WIRING HARNESS REPAIRS»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-special-tools-for-wiring)
2. «CUTTING CABLES TO LENGTH AND STRIP INSULATION»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-cutting-to-length-and)
3. See Recommended Engine Oils For BMW Group Engines See «6113... CRIMPING ANNULAR CONTACTS»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-crimping-annular-contacts) ; «6113... CRIMPING STOP PARTS»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-crimping-stop-parts) ; «6113... CRIMPING MICRO QUADLOCK SYSTEM CONTACTS (MQS)»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-crimping-micro-quadlock-system) or «6113... CRIMPING MICRO POWER QUADLOCK CONTACTS (MPQ)»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-crimping-micro-power-quadlock)
4. «BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-butt-connector-for-repairing)
5. «FAN CONNECTOR FOR RETROFITTING/REPAIRS»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-installing-comb-connector-for)
6. Aerial elbow plug on radio receiver
7. «CUTTING TO LENGTH AND STRIPPING INSULATION FROM OPTICAL FIBRES»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-cutting-off-stripping-insulation)
8. «CRIMPING OPTICAL FIBRES»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-crimping-optical-fibres)
9. Insulation displacement connector for «REPAIRING RIBBON CABLES»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-repairing-ribbon-cables)

61 13... Unlocking and disconnecting different plug connections

Note. Examples of unlocking and disconnecting different plug connections.

Press lock and open clip in direction of arrow.

Disconnect plug connection.

Scheme 1190

Press lock and open clip in direction of arrow.

Disconnect plug connection.

Scheme 1191

Open clip in direction of arrow and disconnect plug connection in direction of arrow.

Scheme 1192

Press lock and disconnect plug connection in direction of arrow.

Scheme 1193

Press lock and disconnect plug connection in direction of arrow.

Scheme 1194

Press lock and disconnect plug connection in direction of arrow.

Scheme 1195

Press lock and disconnect plug connection in direction of arrow.

Scheme 1196

Press lock and disconnect plug connection in direction of arrow.

Scheme 1197

Press lock and disconnect plug connection in direction of arrow.

Scheme 1198

61 00. Version with AFS (Active Front Steering): setting steering angle (after reconnecting vehicle battery)

After RECONNECTING the vehicle battery, carry out the following procedure for setting the steering angle

1. Start engine.
2. Turn steering wheel left to full lock.
3. Turn steering wheel right to full lock.
4. Turn steering wheel to central position.
5. Turn off engine.
6. Turn on ignition (terminal 15), AFS telltale and Check Control message go out.

Note. Entry in the fault memory remains unaffected by this procedure, therefore if necessary: Connect diagnosis system Clear fault memory

61 11... Install the repair cable for the positive battery cable VVT

The repair instructions describe the installation of repair cables for positive battery cable VVT (BMW Parts Department 9 303 031).

Read and comply with notes on HANDLING WIRING HARNESSES AND WIRING !

Read and comply with notes on CRIMPING STOPS !

Necessary preliminary work

Partially remove REAR RIGHT WHEEL ARCH COVER

Remove battery.

Note. Work is shown on the E91 by way of example. There may be differences in detail in the case of other vehicle types and equipment specifications.

Note. Figure shows the following lines (2): Left: Positive battery cable VVT (thinner cable) Right side: Positive battery cable (thicker cable)

Remove positive battery cable VVT left only!

Unclip the left cover (1) and loosen the nut beneath it (tightening torque 8 Nm).

Remove the positive battery cable VVT left (2).

Scheme 1199

Twist tension ring left (1) in direction of arrow and remove.

Installation note

Ensure that the tension rings (1) are correctly seated.

Scheme 1200

Release screws (1).

Slightly lower the cover (2) at the point marked with an arrow.

Scheme 1201

Release screws (1) and cable straps (2) from positive battery cable VVT (3). Lower the cable channel (4) and remove the positive battery cable VVT (3) from the cable channel (4).

Scheme 1202

1. Measure and mark the length (1) = 23 cm on the positive battery cable VVT (2).
2. Disconnect the positive battery cable VVT (2) at the marked point with special tool 2 337 974 (cable shears).
3. At the end of the positive battery cable VVT (2), measure and mark 1 cm.
4. Strip the insulation off the positive battery cable VVT (2) at the marked point with special tool 2 337 974 (cable shears).

Scheme 1203

Attach the heat-shrink tubing (2) on the repair positive battery cable VVT (3).

Position the repair positive battery cable VVT (3) as shown with the arrow.

Crimp the positive battery cable VVT on the vehicle (1) and repair positive battery cable VTT (3) with special tool 61 0 202 .

Scheme 1204

1. Centrally measure and mark distance (1) = 7.5 cm as shown.
2. Position the heat-shrink tubing (2) over the crimping location so that mark (3) is must barely visible.
3. Shrink the heat-shrink tubing (2) with hot air blower 0 444 131. Use soldering shrink reflector (5)! (Heat shrink temperature 400 °C)
4. After shrinking, adhesive (4) must emerge from both sides of the heat-shrink tubing (2).

Note. If the body has corrosion damage in the area of the transfer support point, it must be repaired prior to installing the repair positive battery cable VVT according to the BMW guidelines. Following the completed repair, the body and positive battery connection point must be sprayed with cavity preservation in a diameter of 20 cm.

61 11... Installing the repair cable for the positive battery cable of the power distribution box

Read and comply with notes on HANDLING WIRING HARNESSES AND WIRING !

Read and comply with notes on CRIMPING STOPS !

Necessary preliminary work

Remove GLOVE BOX

Remove JUNCTION BOX

Work is shown on the E90 by way of example.

There may be differences in detail in the case of other vehicle types and equipment specifications.

Disconnect plug connection (1).

Release the wiring harness mounting (2) from the power distribution box (6).

Release screws (3).

Scheme 1205

Disconnect the positive battery cable (2).

Extra plug connections (1) on the back of the power distribution box (3) must not be detached.

Scheme 1206

Open retaining straps (1). Pull out positive battery cable (2) as far as possible.

Scheme 1207

Pre-drill both bridges (2) of the power distribution box (1) at the area marked with an arrow with a 2 mm drill. Then drill through with a 5 mm drill.

Scheme 1208

1. Measure a 15 cm length as shown and mark on the positive battery cable (1).
2. Cut off the positive battery cable (1) at the marked location with special tool 2 337 974 (cable shears).
3. At the cut-off end of the positive battery cable (1), measure and mark 2 cm.
4. Carefully strip insulation off of the positive battery cable (1) at the marked location with special tool 2 337 974 (cable shears).

Scheme 1209

1. Mount the heat-shrink tubing (1) on the repair positive battery cable. Insert the repair positive battery cable as shown in the special tool 2 339 646. (Pliers 2 339 646, die plate 2 339 647)
2. Position the contact (2) as shown.
3. Close special tool. Turn the screw plug (3) anti-clockwise and move it to the position shown.

Scheme 1210

Crimp the vehicle-side positive battery cable (2) and the repair positive battery cable (1) using the special tool 2 339 646.

(Pliers 2 339 646, die plate 2 339 647)

After crimping, copper wires of the vehicle-side positive battery cable (2) must be visible in the opening (3).

Scheme 1211

1. Centrally measure and mark distance = 10 cm as shown.
2. Position the heat-shrink tubing (2) over the crimping location so that mark (3) is must barely visible.
3. Shrink the heat-shrink tubing (2) with a hot air blower 0 444 131 at 400 °C.
4. After shrinking, adhesive (4) must emerge from both sides of the heat-shrink tubing (2).

Scheme 1212

Connect the repair positive battery cable (3) to the power distribution box (1) by pushing down all the way.

Tighten screw (2). Tightening torque: 1, 5 Nm

While tightening the bolt (2), continue pushing down the contact.

Fasten the repair positive battery cable (3) on the power distribution box (1) at the location indicated by the arrow using a cable strap (4).

Scheme 1213

Mount the cap (1) flush.

Scheme 1214

Fasten the positive battery cable (1) at locations (2).

Scheme 1215

The following applies in general

To avoid damage, observe the following instructions

1. Avoid compressive and tensile loads
2. Make sure cables are laid without kinks or abrasions
3. Ensure non-contacting routing at sharp-edged body components; use edge protection if necessary
4. Secure additionally laid cables/lines with cable straps

The following additionally applies

Shielded lines

Contact points in the shield can cause problems with regard to noise radiation and interference immunity. Consequently, distinctions have to be drawn between the following types

Coaxial line

1. Shielded RTK031 coaxial lines may only be repaired with special crimping tool for repairing the coaxial line.

CVBS lines

1. CVBS lines may not be repaired.
2. CVBS lines must be replaced in their entirety.

HSD lines

1. HSD lines may not be repaired.
2. HSD lines must be replaced in their entirety.

Optical fibre cable

Note. Optical fibre cables are colored differently as follows

1. Green = MOST ( M edia O riented S ystems T ransport) optical fibre
2. Yellow = ISIS ( I ntelligent S afety I ntegration S ystem) optical fibre
3. Orange = repair optical fibre cables

TREATING CABLES AND OPTICAL FIBRE CABLES

FlexRay

It is possible to repair the FlexRay. In the event of damage, the cables can be joined with conventional BUTT CONNECTORS .

Note. The line is a twisted cable. If possible, maintain twist in line after repair.

Airbag lines

REPAIRING AIRBAG CABLES

Ribbon cables

REPAIRING RIBBON CABLES Z

Note. Do not connect the charger to the 12 V charging socket

The 12 V charging socket is supplied with voltage by the rear distribution box via relay. This relay drops out after terminal 15 OFF. This means that a trickle charger connected at the 12 V charging socket will be disconnected from the battery. Only charge the battery via the jump start terminal point. Only then can the voltage supply be registered by the vehicle.

1. Do not introduce any additional connections at the battery negative terminal.
2. Do not modify the grounding cable. The grounding cable also serves to dissipate heat.
3. Do not establish any connection between the IBS and the sensor screw.
4. 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.
5. Do not use IBS connections as levers.
6. Use a torque wrench and set tightening torque in accordance with repair instructions.
7. Do not release or tighten down sensor screw (screw with Torx head).
8. Avoid contact between IBS and ground.

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

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

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

SPECIAL TOOLS REFERENCE CHART

Note. Special tools referred to in the repair instructions below are contained in the following special tool kits: Release and press-out tool 61 1 150 is replaced from 09/2005 by 610300 (BMW) and 61 0 400 (MINI) Release and press-out tool 611100 (engine)

Repair instructions for opening plug housings and removing contacts of different plug systems

61 12 013 Replacing battery negative lead

Necessary preliminary tasks

1. Remove «RIGHT LUGGAGE COMPARTMENT TRIM PANEL»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-47-171-removing-and-installingreplacing)
2. Remove «TOP TRIM FROM TAIL PANEL»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-46-050-removing-and-installingreplacing)

Disconnect plug connection (1).

Slacken nut (2) on battery negative terminal.

Tightening torque 61 21 1AZ .

Detach battery negative lead (3) with intelligent battery sensor (IBS) in upward direction.

Release nut (4) and remove cable.

Scheme 1216

Vehicles up to 12/2006 with IBS

Note. IBS2004 is replaced by IBS2006. Remove battery crash element without replacing

Scheme 1217

61 12 002 Replacing battery positive lead (from battery to luggage compartment connector)

Necessary preliminary tasks

1. Remove right «LUGGAGE COMPARTMENT TRIM PANEL»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-47-171-removing-and-installingreplacing)
2. Remove battery cover
3. Disconnect «BATTERY NEGATIVE LEAD»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-20-900-disconnecting-and-connecting)
4. Remove «DISTRIBUTION BOX»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-14-010-removing-and-installingreplacing)
5. Remove «BATTERY»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-21-010-removing-and-installing)

Open cap (1) and release nut underneath.

Remove cable lug mounting from positive battery lead (2).

When installing, ensure

1. Correct screw connection
2. Correct seating of cable lug mounting on positive battery lead (2)
3. Tightening torque «61 12 1AZ»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-tightening-torques-e90) .

Scheme 1218

Replacement with build date up to 03/2006

Connect repair cable for battery terminal (1) to safety battery terminal (2).

Install BATTERY .

Install DISTRIBUTION BOX .

Scheme 1219

Cut off plug connection (1) and connect to battery terminal repair cable (2).

Follow notes for REPAIRING AIRBAG LEADS .

Secure battery terminal repair cable (2).

Scheme 1220

61 12 004 Replacing battery positive lead (from luggage compartment connector to engine bulkhead connector)

Necessary preliminary tasks

1. Remove «BATTERY»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-21-010-removing-and-installing)
2. Remove «FUEL TANK»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-11-030-removing-and-installing)
3. Partially remove front right «WHEEL ARCH TRIM»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-71-039-removing-and-installingreplacing)
4. Remove «COVER FROM ELECTRONICS BOX»(/bmw/m3/e90-2007-2013/remont/gauges-instrument-panels/#engine-electrical-system-repair-e90__12-90-removing-and-installingreplacing-electronics)

Work is shown on the E82 N52N by way of example. There may be differences in detail in the case of other vehicle models.

Unclip covers (1) and release nuts underneath.

Tightening torque 61 12 1AZ .

Disconnect battery positive leads (2).

Turn clamping rings (1) in direction of arrow and remove.

Installation

Make sure clamping rings (1) are correctly seated.

Remove battery positive lead (1) from luggage compartment floor (2).

Scheme 1221

Release bolt (1) and nut (2).

Remove cover (3).

Scheme 1222

Release holder (1) from body.

Feed out battery positive leads (2) and vent line (4) from holder (1).

Release retaining clips (3) and remove vent line (4) from cover (5).

Release all nuts and remove cover (5).

Scheme 1223

Release attachment points for battery positive lead (1) from body.

Scheme 1224

Note. Electronics box shown removed for purposes of clarity.

Unclip cover cap (1).

Release nuts underneath.

Tightening torque 61 12 4AZ .

Remove positive battery cable.

Scheme 1225

Release wiring harness holder (1).

Feed out battery positive lead in direction of arrow.

Scheme 1226

61 12 200 Replacing wiring harness in left or right front door

Necessary preliminary tasks

1. Close front side window completely
2. Remove «FRONT DOOR TRIM PANEL»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-41-000-removing-and-installing)
3. Remove «FRONT ACOUSTIC INSULATION»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-48-060-removing-and-installingreplacing)

Unlock plug connection (1) on door lock and disconnect.

Unlock plug connection (4) on power window and disconnect.

Disconnect plug connection (2) on outside door handle light.

Disconnect plug connection (5) on door mirror.

Unclip door wiring harness at points (3).

Scheme 1227

Installation

Make sure door wiring harness is correctly laid.

Release screw (1), fold door wiring harness plug on A-pillar (2) downwards slightly and remove.

Unlock plug connection behind and disconnect.

Pull rubber grommet (3) out of front door.

Feed out door wiring harness towards front to A-pillar and remove.

Scheme 1228

61 12 210 Replacing wiring harness in left or right rear door

Necessary preliminary tasks

1. Close rear side window completely
2. Remove «REAR DOOR TRIM PANEL»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-42-000-removing-and-installing)
3. Remove «REAR ACOUSTIC INSULATION»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-48-070-removing-and-installingreplacing)

Unlock plug connection (1) on door lock and disconnect.

Unlock plug connection (2) on power window and disconnect.

Disconnect plug connection (3) on outside door handle light.

Unclip door wiring harness at points (4).

Installation

Make sure door wiring harness is correctly laid.

Scheme 1229

Release screw (1), fold door wiring harness plug on B-pillar (2) downwards slightly and remove.

Unlock plug connection behind and disconnect.

Pull rubber grommet (3) out of rear door.

Feed out door wiring harness towards front to B-pillar and remove.

Note. Examples of unlocking and disconnecting different plug connections.

Press lock and open clip in direction of arrow.

Disconnect plug connection.

Press lock and open clip in direction of arrow.

Disconnect plug connection.

Open clip in direction of arrow and disconnect plug connection in direction of arrow.

Press lock and disconnect plug connection in direction of arrow.

Press lock and disconnect plug connection in direction of arrow.

Press lock and disconnect plug connection in direction of arrow.

Press lock and disconnect plug connection in direction of arrow.

Press lock and disconnect plug connection in direction of arrow.

Press lock and disconnect plug connection in direction of arrow.

61 13... Butt connector for repairing a plug connection

Note. The repair range IV for vehicle electrical system contained the required special tools and individual parts for retrofitting and repair work with the aid of fan connectors.

Scheme 1230

Choose repair kit.

Example: Repair kit, circular plug system D 2.5.

Scheme 1231

Remove following parts

1. Pre-packaged end of cable with requisite wire cross-section
2. Crimp connector for selected wire cross-section
3. Shrink-fit hose

Scheme 1232

Open secondary lock on housing.

Mark damaged contact (4) with socket number of housing and press it out of housing using appropriate special tool contained in special tool kit 610300.

See repair instructions

OPENING PLUG HOUSINGS AND REMOVING CONTACTS of different plug systems

Scheme 1233

Scheme 1234

Adhere to following procedure

1. Cut off wire with faulty contact at point which is easily accessible
2. Strip insulation from end of wire at wiring harness end
3. Cut preassembled wire end to length and strip insulation

Refer also to repair instruction

CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES

Crimp butt connector on preassembled wire end.

See repair instructions

CRIMPING ON STOP PARTS

Scheme 1235

Push shrink-fit hose (8) onto free wire end.

Scheme 1236

Crimp unused wire end to butt connector.

Scheme 1237

Pull shrink-on sleeve over butt connector.

Scheme 1238

With hot air blower, shrink the shrink-on sleeve on both sides (9) of shrink-fit hose until glue emerges uniformly all round.

Insert contact in housing.

Close secondary lock on housing.

Scheme 1239

Notes

Socket housing

Press lock (1) with suitable tool (2) in direction of arrow out of socket housing (3).

Scheme 1240

Pull lock (1) out of socket housing (2).

Scheme 1241

Insert special tool 61 0 317 into socket housing (1) and pull out lead with LCC contact (2) in direction of arrow.

Scheme 1242

Pin housing

Unlock locking slide (1) of pin housing (2) with suitable tool (3) in direction of arrow.

Scheme 1243

Insert special tool 61 0 317 into pin housing (1) and pull out lead with LCC contact (2) in direction of arrow.

Scheme 1244

61 13... Crimping Micro Power Quadlock contacts (MPQ)

To crimp MPQ contacts, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 325 (2) from crimping set 614320.

Note. Pliers (1) open automatically as far as they will go when handles are pressed together.

Scheme 1245

Open pliers (1).

Note. Place contact (2) with utmost care in designated nest (observe cable cross-section) in crimping head (3). Make sure it is exactly positioned.

Place MPQ contact (2) in crimping head (3).

Close pliers (1) one notch.

Scheme 1246

Note. Follow procedure for CUTTING AND STRIPPING INSULATION from cables.

Insert stripped cable (2).

Close pliers (1) fully.

Open pliers (1) and remove cable (2).

Note. CHECK CONTACT FOR CORRECT CRIMPING .

Scheme 1247

61 13... Crimping Micro Quadlock System contacts (MQS)

To crimp MPQ contacts, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 324 (2) from crimping set 614320.

Note. Pliers (1) open automatically as far as they will go when handles are pressed together.

Scheme 1248

Open pliers (1).

Fold up contact carrier (2).

Insert MQS contact (3) in contact carrier (2).

Fold back contact carrier (2).

Scheme 1249

Note. Follow procedure for CUTTING AND STRIPPING INSULATION from cables.

Close pliers (1) one notch.

Insert stripped cable (2).

Close pliers (1) fully.

Scheme 1250

Open pliers (1).

Open contact carrier (2) gently and carefully remove MQS contact.

Note. CHECK CONTACT FOR CORRECT CRIMPING .

Scheme 1251

61 13... Crimping annular contacts

Crimping annular contacts

Special tool 614320

Handling

61 13... Crimping optical fibres

To crimp optical fibres, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 323 (2) from crimping set 614320.

Note. Pliers (1) open automatically as far as they will go when handles are pressed together.

Scheme 1252

Move contact guide by means of stop lever (1) into corresponding position (pin contact or jack).

Scheme 1253

Open pliers (2).

Place pin contact or jack (1) in crimping head and secure with locking lever (3).

Scheme 1254

Note. Follow procedure for CUTTING AND STRIPPING INSULATION FROM OPTICAL FIBRES .

Insert stripped optical fibre (1) as far as it will go into pin contact or jack (2).

Close pliers (3) fully.

Open pliers (3) and locking lever (4).

Remove optical fibre (1).

Scheme 1255

Right (A)

End of optical fibre (1) must be flush with tip of pin contact (2).

Wrong (B)

End of optical fibre (1) is not flush with tip of pin contact (2).

Scheme 1256

61 13... Crimping stop parts

Spare parts for in-car electronics (housing and contacts)

1. Crimping butt connectors and contact sleeves for fan connectors up to 2.5 mm

2. Crimping butt connectors and contact sleeves for fan connectors larger than 2.5 mm 2

3. Crimping contact sleeves for 4 mm 2 fan connectors and ignition cable contacts

Use special tool kit 12 1 080 to attach ignition cable contacts and crimp 4 mm 2 contact sleeves for fan connectors.

1. 12 1 081 (hand pliers)
2. 12 1 083 (nest)

See repair instructions

SPECIAL TOOLS FOR WIRING HARNESS REPAIRS.

Scheme 1257

Release special tool 12 1 081

Squeeze grips (1) lightly and push unlocking lever (2) in direction of arrow.

Or

Compress handles as far as they will go, tool unlocks automatically.

Scheme 1258

Place 4 mm 2 contact sleeve in nest with anti-twist safeguard (1) as far as possible.

Scheme 1259

Preload contact by squeezing matrix in crimping tool. Grip contact (1) firmly only, do not crimp.

Scheme 1260

Note. Follow procedure for CUTTING AND STRIPPING INSULATION from cables.

Insert stripped end of wire (7) in the contact. Ensure insulation and stripped wire end are correctly laid in contact.

Compress crimping tool as far as it will go.

Crimping tool unlocks automatically.

Take contact out of crimping tool.

Scheme 1261

4. Checking crimping

Check insulation crimp (8) and wire crimp (9) against following illustrations to ensure crimps are correctly located.

Note. Illustration shows butt connectors and contact sleeves for fan connectors knocked on one side. The crimping procedure is identical here.

Scheme 1262

Correct crimping

Visible conductor end (10).

Visible insulation end (11).

Scheme 1263

Incorrect crimping

Conductor end (10) inserted too far.

Insulation end (11) in wire crimp.

If necessary, repeat crimping with a new contact.

Scheme 1264

Incorrect crimping

Conductor end (10) not visible.

Insulation end (11) not visible.

If necessary, repeat crimping with a new contact.

Scheme 1265

61 13... Cutting off, stripping insulation and cutting optical fibres to length

To cut off, strip insulation and cut optical fibres to length, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 322 (2) from crimping set.

Note. Pliers (1) open automatically as far as they will go when handles are pressed together.

Scheme 1266

Cutting optical fibre

Open pliers (1).

Place optical fibre (2) in cutting device (3).

Close pliers (1) and remove optical fibre (2).

Scheme 1267

Stripping insulation from optical fibre

Open pliers (1).

Open lever (2) in direction of arrow.

Scheme 1268

Slide optical fibre (1) into stripping device (2) until flush at point (3).

Close pliers (4) fully.

Close clamping lever (5) in direction of arrow.

Open pliers (4) by one tooth notch.

Open clamping lever (5) against direction of arrow again and remove optical fibre (1).

Note. A stripping replacement blade set is available under number 61 4 327.

Scheme 1269

Cutting optical fibre to length

Pull pin (1) in direction of arrow.

Fold up blade retaining link (2) in direction of arrow.

Scheme 1270

Remove blade (1) and replace.

Installation

Make sure blade (1) is correctly seated on locating points (2).

Scheme 1271

Open pliers (3).

Slide optical fibre (1) into cutting device (2) until insulation of optical fibre (1) butts against clamping device.

Close pliers (3) fully and keep closed.

Remove optical fibre (1).

Scheme 1272

61 13... Cutting to length and stripping insulation from cables

Stripped length

WIRE STRIPPED LENGTH REFERENCE CHART

61 13... Fuse holder

Remove appropriate fuse from fuse holder (1).

Note. Identify the position when removing fuses.

Pull sliding lock (2) out of fuse holder (1) completely.

Scheme 1273

With special tool 61 1 136 or 61 1 137 (pressing-off tool), press back retaining hooks (3) of appropriate contact and pull out cable.

Scheme 1274

61 13... In-line plugs, 2-pin, System JPT ELA

Press lock (1) in direction of arrow and slide connector forward.

Scheme 1275

Press lock (1) downward and slide out to one side.

Scheme 1276

With special tool 61 0 316 from kit 61 0 300 , unlock contact and pull out cable (1) with contact towards rear.

Scheme 1277

61 13... In-line plugs, 24- pin, Hybrid System MQS/MPQ

Manufactured by AMP: The following contact types without strand sealing can be fitted in the plug housings

1. MQS (Micro Quadlock System)
2. MPQ, width 2.8 mm (Micro Power Quadlock)
3. MPQ, width 5.2 mm (Micro Power Quadlock)

Socket housing

Press locks (1) on cap (2) upwards on both sides.

Detach cap from contact carrier (3).

Note. Detaching the cap releases the secondary locks of the socket contacts.

Scheme 1278

Hold down retaining hook (1) of socket contact in opening of contact carrier with a small screwdriver.

Pull wire with socket contact in direction of arrow as far as secondary lock (2).

Scheme 1279

Hold down retaining hook in secondary lock (1) again and pull cable with socket contact (2) completely out of contact carrier (3).

Scheme 1280

Pin housing

Press locks (1) on cap (2) upwards on both sides.

Detach cap from housing carrier (3).

Note. Detaching the cap releases the secondary locks of the pin contacts in the contact carriers.

Scheme 1281

Pull contact carrier (1) out of housing carrier (2).

The pin contacts are pulled out of a contact carrier as described under "Socket housing".

Scheme 1282

61 13... In-line plugs, 30- pin, Hybrid System MQS/MPQ

Manufactured by AMP: The following contact types without strand sealing can be fitted in the plug housings

1. MQS (Micro Quadlock System)
2. MPQ, width 2.8 mm (Micro Power Quadlock)
3. MPQ, width 5.2 mm (Micro Power Quadlock)

Socket housing

Raise lock (1) on housing (2).

Push contact carrier (3) from rear out of housing (2).

Note. Pushing out the contact carrier releases the secondary locks of the socket contacts.

Scheme 1283

Hold down retaining hook (1) of socket contact in opening of contact carrier with a small screwdriver.

Pull wire with socket contact in direction of arrow as far as secondary lock (2).

Hold down retaining hook in secondary lock (1) again and pull cable with socket contact (2) completely out of contact carrier (3).

Pin housing

Contacts 1... 13 and 19... 27

Raise locking slide (1) on both sides (2) of housing and detach.

Note. Detaching the locking slide releases the secondary locks of the pin contacts.

Scheme 1284

Contacts 14... 18 and 28... 30

Pull slide (1) outwards completely.

Raise lock (2) on housing.

Pull contact carrier (3) out of housing.

Note. Pulling out the contact carrier releases the secondary locks of the pin contacts.

Scheme 1285

The pin contacts are pulled out of a contact carrier as described under "Socket housing".

61 13... In-line plugs, 6- to 50-pin, System Elo

Unlock lock.

Scheme 1286

Unfasten cable strap.

Installation

Cable clip must be reinstalled.

Scheme 1287

Detach catch (1) from plug housing (2).

Scheme 1288

Press out contact carrier (3) with wiring harness (4) through opening (5).

Scheme 1289

Hold down arrester hook (6) of defective contact and pull cable and contact up to secondary lock (8).

Scheme 1290

Hold down arrester hook once again in secondary lock (8) and pull cable and contact completely out of contact carrier.

Scheme 1291

61 13... Inline plugs, 6-, 8- pin, System MQS

Press lock (1) in direction of arrow and slide plug forward.

Scheme 1292

Press locking hook (2) downward and slide lock (1) out.

Scheme 1293

Press down arrester hook (1) with screwdriver and pull out cable with contact towards rear.

Scheme 1294

61 13... Inline plugs, 8-, 12-pin, System D2.5

Move upper section of connector (1) and lower section of connector (2) against each other in direction of arrow.

Scheme 1295

With special tool 61 0 313 from kit 61 0 300 , press back retaining hook (3) of corresponding contact and pull out cable with contact.

Scheme 1296

61 13... Installing comb connector for retrofitting/repairs

Note. The repair range IV for vehicle electrical system contained the required special tools and individual parts for retrofitting and repair work with the aid of fan connectors.

1. Special tool «61 9 040»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-special-tools-e9293__61-9-040-set-of-tools)

Choose contact sleeve (up to 4 mm 2 ) in accordance with wire cross-section.

Scheme 1297

Scheme 1298

Alternatively

Choose contact sleeves (up to 2.5 mm 2 ) for fan connectors.

Scheme 1299

Cut through wire loop in wiring harness at established point.

Strip insulation from both wire ends.

See repair instructions

Scheme 1300

Crimp contact sleeves on both wire ends.

See repair instructions

CRIMPING ON STOP PARTS

Note. If using repair kit for contact sleeves, refer to repair instruction: BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION .

Scheme 1301

Crimp connecting cable for retrofitting likewise with contact sleeve.

Scheme 1302

Cut required number of poles to length for fan connectors.

Scheme 1303

Special tool 61 9 041 (hand crimping tool) in conjunction with 61 9 042 (matrix) are used for pushing contact sleeves onto fan connectors.

See repair instructions

SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

Scheme 1304

Unlock special tool 61 9 041

Squeeze grips (1) lightly and push unlocking lever (2) in direction of arrow.

Or

Compress handles as far as they will go, tool unlocks automatically.

Scheme 1305

Insert prepared fan connectors (3) in special tool 61 9 041/61 9 042.

Scheme 1306

Attach wire with contact sleeve to fan connector.

Scheme 1307

Press crimping tool together and slide contact sleeve firmly home.

Scheme 1308

Push on further contact sleeves for potential branching.

Scheme 1309

Installation in wet area (engine compartment, wheel arch)

Apply sealing compound on both sides and press into contacts (1).

Fit shrink-fit hose and heat up with hot air blower (2) (approx. 250°C).

Note. Ensure that fan connector has sufficient contact surface on mounting point.

Do not heat shrink-fit hose on edges of fan connector too strongly, risk of cracking.

Allow shrink-fit hose to cool down until hand-warm. Then press sealing material again into contacts and onto edges of fan connector.

If necessary, carefully heat shrink-fit hose again.

Scheme 1310

Installation in dry area (interior, luggage compartment)

Slide assembled fan connector into insulation housing until it locks into place.

Scheme 1311

61 13... Main relay connector for DME

Open locking clip (1) for the corresponding cable.

Scheme 1312

With special tool 61 1 136 or 61 1 137 (pressing-off tool), press back retaining hooks (2) of appropriate contact and pull out cable with contact.

Scheme 1313

Note. The optical fibres are colored differently as follows: Green = MOST ( M edia O riented S ystems T ransport) optical fibre Yellow = ISIS ( I ntelligent S afety and I ntegration S ystem) fibre-optic cable Orange=repair fibre-optic cables

Follow instructions for PROCESSING CABLES AND OPTICAL FIBRES .

The following applies in general

To avoid damage, observe the following instructions

1. Avoid compressive and tensile loads
2. Make sure cables are laid without kinks or abrasions
3. Ensure non-contacting routing at sharp-edged body components; use edge protection if necessary
4. Secure additionally laid cables/lines with cable straps

The following additionally applies

Shielded lines

Contact points in the shield can cause problems with regard to noise radiation and interference immunity. Consequently, distinctions have to be drawn between the following types

Coaxial line

1. Shielded RTK031 coaxial lines may only be repaired with special crimping tool for repairing the coaxial line.

CVBS lines

1. CVBS lines may not be repaired.
2. CVBS lines must be replaced in their entirety.

HSD lines

1. HSD lines may not be repaired.
2. HSD lines must be replaced in their entirety.

Optical fibre cable

Note. Optical fibre cables are colored differently as follows

1. Green = MOST ( M edia O riented S ystems T ransport) optical fibre
2. Yellow = ISIS ( I ntelligent S afety I ntegration S ystem) optical fibre
3. Orange = repair optical fibre cables

TREATING CABLES AND OPTICAL FIBRE CABLES

FlexRay

It is possible to repair the FlexRay. In the event of damage, the cables can be joined with conventional BUTT CONNECTORS .

Note. The line is a twisted cable. If possible, maintain twist in line after repair.

Airbag lines

REPAIRING AIRBAG CABLES

Ribbon cables

REPAIRING RIBBON CABLES Z

SPECIAL TOOLS REFERENCE CHART

Ultrasonic-welded connectors (1) can be identified by the welds (2) on their longitudinal side.

Note. Special tools referred to in the repair instructions below are contained in the following special tool kits: Release and press-out tool 61 1 150 is replaced from 09/2005 by 610300 (BMW) and 61 0 400 (MINI) Release and press-out tool 611100 (engine)

Repair instructions for opening plug housings and removing contacts of different plug systems

61 13... Plug housing, LCC contact (load current contact)

Socket housing

Press lock (1) with suitable tool (2) in direction of arrow out of socket housing (3).

Pull lock (1) out of socket housing (2).

Insert special tool 610317 into socket housing (1) and pull out lead with LCC contact (2) in direction of arrow.

Pin housing

Unlock locking slide (1) of pin housing (2) with suitable tool (3) in direction of arrow.

Insert special tool 610317 into pin housing (1) and pull out lead with LCC contact (2) in direction of arrow.

61 13... Relay carrier

Place special tool 61 1 153 against relay carrier (1) and carefully pull in direction of arrow until the locking tabs (2) of the relay carrier are raised up.

Scheme 1314

Pull relay carrier (2) in direction of arrow into the first catch (3).

Scheme 1315

Press down arrester hook (4) of corresponding contact and pull out the cable with contact.

With special tool 61 1 136 or 61 1 137 (press out) press out dual spring contacts.

Scheme 1316

61 13 050 Removing and installing or replacing fuse box in passenger compartment (built after 03/2007)

Necessary preliminary tasks

1. Remove right «GLOVEBOX»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-16-366-removing-and-installing) with housing
2. Remove «JUNCTION BOX»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-35-107-removing-and-installing)

Disconnect plug connection (1).

Release wiring harness fastener (2) from fuse box interior (6).

Release screws (3).

Disconnect all plug connections (1) on reverse side of fuse box interior (3).

Remove fuse box interior (3).

Installation

Battery positive lead (2) must not be damaged.

Make sure wiring harnesses are correctly laid and plug connections (1) are correctly engaged.

Replacement

If necessary, remove fuses and relays.

61 13... Removing and installing/replacing OBD-II socket

Necessary preliminary tasks

1. Remove «FOOTWELL SIDE TRIM PANEL ON A-PILLAR, LEFT»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-43-070-removing-and-installingreplacing)

Release screws (1).

Remove OBD-II socket (2) from holder (3).

Scheme 1317

Remove OBD-II socket cover (2) from OBD-II socket (1).

Unlock slide plate (3) with a suitable tool in direction of arrow.

Insert special tool 610315 in OBD-II socket (1) in direction of arrow and press out associated flat spring contact (4). Press remaining flat spring contacts with special tool 610315 out of OBD-II socket (1).

Installation

Pay attention to pin assignment of OBD-II socket (1).

Make sure flat spring contacts and slide plate (3) are correctly engaged and seated in OBD-II socket (1).

Scheme 1318

61 31 134 Removing and installing/replacing USB/audio interface connecting socket

Operation is described in

Removing and installing/replacing AV CONNECTION SOCKET

Safety regulations

Safety regulations for HANDLING COMPONENTS OF AIRBAG SYSTEM .

INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .

Procedure for cable repair

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 .

61 13... Repairing airbag leads (build date/version affected 04/2008 to 07/2008)

Switch off ignition!

Necessary preliminary tasks

1. Move driver's seat/front passenger seat fully back and upwards.

Unlock plug connections (1) and disconnect.

Disconnect plug (2).

Scheme 1319

Release cable tie (1).

Unlock cap (2) on both sides and pull out in direction of arrow.

Installation

Secure wiring harness for strain relief with cable tie on plug housing.

Scheme 1320

Scheme 1321

Strip insulation (1) and disconnect cables in accordance with table.

CABLE DISCONNECTION REFERENCE CHART - DRIVER SEAT

CABLE DISCONNECTION REFERENCE CHART - PASSENGER SEAT

Cut cable (1) with BMW-recommended cable stripper and strip insulation.

1. Dimension A = 11 cm

Scheme 1322

Cut repair cable (1) with BMW-recommended cable stripper and strip insulation.

Cut repair wiring harness 11 cm.

1. Dimension A = 11 cm

Scheme 1323

Connect repair cable (1) with butt connector to vehicle wiring harness.

1. Universal matrix 61 4 328
2. Pliers 61 4 321

Scheme 1324

Slide SHRINK-ON HOSES (1) over ignition circuit leads (2).

With hot-air blower, shrink the shrink-on hose on both sides of shrink-on hose until glue emerges uniformly all round.

Scheme 1325

Connect ignition circuit lead (1) with special tool 610327 in accordance with table.

Scheme 1326

61 13... Repairing ribbon cables

Place ribbon cables (1) in connector housing (2) and close cover (3).

Scheme 1327

Place connector housing (1) in tool (2) 611190.

Close tool (2).

Scheme 1328

61 13... 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

1. MQS (Micro Quadlock System)
2. MPQ, width 2.8 mm (Micro Power Quadlock)
3. MPQ, width 5.2 mm (Micro Power Quadlock)

Removing MPQ contacts from radio plug

Press lock (1) in direction of arrow.

Detach secondary lock (2) from radio plug.

Scheme 1329

Feed special tool 61 1 135 past side of contact.

Press special tool 61 1 135 in direction of arrow.

Pull wire (1) with socket contact out of radio plug (2).

Scheme 1330

Removing MQS contacts from contact carrier

Press lock (1) in direction of arrow and pull housing (2) out of radio plug.

Scheme 1331

Press lock (1) in direction of arrow. Pull contact carrier (2) out of housing (3).

Note. When the contact carrier is pulled out, the secondary locks of the socket contacts are raised.

Scheme 1332

Hold down retaining hook (1) of socket contact in opening of contact carrier with a small screwdriver.

Pull wire with socket contact in direction of arrow as far as secondary lock (2).

Note. The illustration shows an 8-pin female connector housing where contact removal is identical.

Depress retaining hook in secondary lock (1) once again. Remove wire with female contact (2) from contact carrier (3) completely.

Removing MPQ contacts from contact carrier

Remove contact carrier (1) with MQS contacts from the radio plug.

Raise lock (2) on radio plug.

Remove contact carrier (3) from radio plug.

Scheme 1333

Press lock (1) in direction of arrow.

Pull secondary lock (2) in the direction of the arrow and out of contact carrier (3) completely.

Scheme 1334

Press special tool 61 1 135 against inside of contact in contact carrier (2).

Remove wire with female contact (1) from contact carrier (2).

Scheme 1335

61 13... 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

1. MQS (Micro Quadlock System)
2. MPQ, width 2.8 mm (Micro Power Quadlock)
3. MPQ, width 5.2 mm (Micro Power Quadlock)

Open secondary locks (1) on socket housing.

Press back retaining hook of MQS contacts (2) with special tool 61 1 134 and pull out cable with contact.

Press back retaining hook of MPQ contacts (3) with screwdriver or similar tool and pull out cable with contact.

Scheme 1336

Installation

Bend open retaining hook of contacts gently before inserting into plug housing.

To install contacts, observe cavity numbers on reverse side of socket housing.

Scheme 1337

61 13... 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

1. MQS (Micro Quadlock System)
2. MPQ, width 2.8 mm (Micro Power Quadlock)
3. MPQ, width 5.2 mm (Micro Power Quadlock)

Manufactured by Siemens: The following contact types without strand sealing can be fitted in the socket housings

1. Elo (electronic contact)
2. Elo-Power 2.8 mm wide (electronic contact for heavy loads)
3. Elo-Power 5.2 mm wide (electronic contact for heavy loads)

Raise lock (1) on housing (2).

Push contact carrier (3) from rear out of housing.

Note. The second contact carrier is pushed out in the same way. Pushing out the contact carrier releases the secondary locks of the socket contacts.

Scheme 1338

Hold down retaining hook (1) of socket contact in opening of contact carrier with a small screwdriver.

Pull wire with socket contact in direction of arrow as far as secondary lock (2).

Hold down retaining hook in secondary lock (1) again and pull cable with socket contact (2) completely out of contact carrier (3).

61 13... Socket of tab connector housings

Unlock hooks (1) with special tool 61 1 360 and push plug housing out of the socket.

Scheme 1339

61 13... Special tools for wiring harness repairs

1. Special tool 610300
2. Special tool 61 0 400 (MINI N12/N14)

Handling

1. «OPENING PLUG HOUSINGS AND REMOVING CONTACTS»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-opening-plug-housings-and) of different plug systems

Scheme 1340

Handling

1. «CUTTING CABLES TO LENGTH AND STRIP INSULATION»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-cutting-to-length-and)

Crimping stop parts (small contacts)

Scheme 1341

1. Special tool 614320 Tool without crimping head Crimping head «(STRIPPING INSULATION AND CUTTING FIBRE-OPTIC CABLES TO LENGTH)»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-cutting-off-stripping-insulation) Crimping head «(CRIMPING FIBRE-OPTIC CABLE CONTACTS)»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-crimping-optical-fibres) Crimping head «(CRIMPING MQS CONTACTS)»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-crimping-micro-quadlock-system) Crimping head «(CRIMPING MPQ CONTACTS)»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-crimping-micro-power-quadlock) Replacement blade (face-cutting fibre-optic cables) Replacement blade with tool (insulation stripping unit) Universal crimping head

Crimping stop parts (large contacts)

1. Special tool 610200 (crimping set)
2. Special tool 610210 (matrix set)
3. Special tool 610220 (matrix set SLK 2.8)
4. Special tool 610230 (matrix set MAK 8/DFK4)

Handling

Scheme 1342

Crimping antenna elbow plugs

1. Special tool 61 9 041 (pliers)
2. Special tool 61 9 044 (matrix)

Handling

1. Antenna elbow plug on radio receiver

Scheme 1343

Repair kit for ignition cables and for crimping fan connector receptacles 4 mm 2

1. Special tool 12 1 080

Handling

1. «CRIMPING STOP PARTS (CONTACTS)»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-crimping-stop-parts)

Scheme 1344

Repairing ribbon cables

1. Special tool 611190

Handling

1. «REPAIRING RIBBON CABLES»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-repairing-ribbon-cables)

Scheme 1345

Note. Special tools referred to in the repair instructions below are contained in the following special tool kits

SPECIAL TOOL REFERENCE CHART

Subject of repair instructions

1. «SPECIAL TOOLS FOR WIRING HARNESS REPAIRS»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-special-tools-for-wiring)
2. «CUTTING CABLES TO LENGTH AND STRIP INSULATION»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-cutting-to-length-and)
3. See Recommended Engine Oils For BMW Group Engines See «6113... CRIMPING ANNULAR CONTACTS»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-crimping-annular-contacts) ; «6113... CRIMPING STOP PARTS»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-crimping-stop-parts) ; «6113... CRIMPING MICRO QUADLOCK SYSTEM CONTACTS (MQS)»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-crimping-micro-quadlock-system) or «6113... CRIMPING MICRO POWER QUADLOCK CONTACTS (MPQ)»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-crimping-micro-power-quadlock)
4. «BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-butt-connector-for-repairing)
5. «FAN CONNECTOR FOR RETROFITTING/REPAIRS»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-installing-comb-connector-for)
6. Aerial elbow plug on radio receiver
7. «CUTTING TO LENGTH AND STRIPPING INSULATION FROM OPTICAL FIBRES»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-cutting-off-stripping-insulation)
8. «CRIMPING OPTICAL FIBRES»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-crimping-optical-fibres)
9. Insulation displacement connector for «REPAIRING RIBBON CABLES»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-13-repairing-ribbon-cables)

Note. Examples of unlocking and disconnecting different plug connections.

Press lock and open clip in direction of arrow.

Disconnect plug connection.

Press lock and open clip in direction of arrow.

Disconnect plug connection.

Open clip in direction of arrow and disconnect plug connection in direction of arrow.

Press lock and disconnect plug connection in direction of arrow.

Press lock and disconnect plug connection in direction of arrow.

Press lock and disconnect plug connection in direction of arrow.

Press lock and disconnect plug connection in direction of arrow.

Press lock and disconnect plug connection in direction of arrow.

Press lock and disconnect plug connection in direction of arrow.

61 42... Removing and installing/replacing DC/DC converter

Note. DC/DC converter in vehicles with automatic start-stop function.

There are two versions

1. Without additional bracket for diesel engine vehicles
2. With additional bracket for gasoline engine vehicles

Depending on the equipment, one or both versions are installed in the M3

Necessary preliminary work

Remove lower section of microfilter housing (all except M3)

Remove RIGHT UPPER SECTION OF MICROFILTER HOUSING M3

Unlock fasteners (1) from below and slide upwards approx. 10 mm.

Unlock locks (2) in direction of arrow.

Remove cover (3).

Scheme 1346

Diesel engine vehicles (without additional bracket)

Release lugs in direction of arrow. Remove DC/DC converter (1) by pulling upward. Disconnect plug connection (2).

Scheme 1347

Gasoline engine vehicles (with additional bracket)

Release lugs in direction of arrow. Remove DC/DC converter (1) by pulling upward. Disconnect plug connection (2).

Scheme 1348

M3

Release tabs in direction of arrow and remove DC/DC converter with additional bracket (1) upward. Disconnect plug connection (2).

Release tabs in direction of arrow and remove DC/DC converter without additional bracket (3) upward. Disconnect plug connection (4).

Scheme 1349

61 14 010 Removing and installing/replacing distribution box (on battery)

Necessary preliminary tasks

1. Remove «FLAP IN LUGGAGE COMPARTMENT PANEL»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-47-171-removing-and-installingreplacing) on right
2. Disconnect «BATTERY NEGATIVE LEAD»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-20-900-disconnecting-and-connecting)

Release screws (1) and remove bracket (2). Tightening torque 61 14 1AZ .

Scheme 1350

Disconnect plug connection (1).

Unlock plug housing (2) and release in direction of arrow.

Fold up covers on nuts (3).

Unscrew nuts (3). Tightening torque 61 21 2AZ .

Disconnect plug connection (4).

Disconnect plug connection of IBS cable (5).

Scheme 1351

Press locking brackets (2) downwards and unclip.

If necessary, using a screwdriver (1), expand locking bracket (2) at lower end and clip out.

Remove power distributor (3) towards top.

Scheme 1352

61 14... Removing and installing/replacing engine compartment B+ terminal

Necessary preliminary tasks

1. Remove «COVER FROM ELECTRONICS BOX»(/bmw/m3/e90-2007-2013/remont/gauges-instrument-panels/#engine-electrical-system-repair-e90__12-90-removing-and-installingreplacing-electronics)

Note. Work is shown on the E82 N52N by way of example. There may be differences in detail in the case of other vehicle models.

Unclip covers (1) and release nuts underneath. Tightening torque 61 12 4AZ .

Remove battery positive cables.

Unclip cover (1).

Scheme 1353

Unscrew nuts (1). Tightening torque 61 12 4AZ .

Remove battery positive cables.

Release locks (2) and remove frame (3) towards rear from B+ terminal.

Unclip B+ terminal and remove towards front.

Scheme 1354

Installation

Make sure frame (3) engages correctly in B+ terminal.

Scheme 1355

Introduction

In September 2002, the first so-called VRLA batteries, better known as AGM batteries came into use. (VRLA means V alve R egulated L ead A cid, i.e. lead acid battery with pressure relief valve; AGM stands for A bsorbent G lass Mat , i.e. absorbent glass-fibre fleece)

AGM batteries are fitted in models with electrical loads/consumers which have a high energy demand.

With the option SA 146 (2nd battery), the AGM battery (70 Ah) is fitted as the 2nd battery.

The constantly increasing energy demand of modern vehicle electrical systems calls for ever more powerful battery solutions. A modern luxury-class vehicle has some 100 actuator motors that have to be fed with electrical current. Added to these are safety, environmental and comfort and convenience elements which are increasingly becoming standard features, such as e.g. Anti-lock Brake System (ABS), Dynamic Stability Control (DSC), electric steering effort assistance (EPS), heated catalytic converter, electronic chassis and suspension control, air conditioning and navigation system. Current consumption is considerable even when the vehicle is not in use.

The somewhat higher price compared with a battery of similar size is fully balanced by the following benefits

1. greatly longer service life
2. improved starting reliability at low temperatures
3. reliable starting of engines with high starting current requirements, e.g. high-performance diesel engines
4. 100 % freedom from maintenance
5. low risk in the event of an accident (reduced environmental risk)

Service life of AGM batteries

Scheme 1356

AGM BATTERY CAPACITY

In contrast to conventional lead-calcium batteries, the sulfuric acid in a battery with fleece technology is not held freely in the battery housing. Rather, 100% of the sulfuric acid is bound into the mats of the glass-fibre fleece (separators). For this reason, no acid can escape if the battery housing is damaged. In addition, the AGM battery is sealed to be airtight. This is possible because the gases are converted back into water as a result of the separator permeability.

Brief component description

An AGM battery can be recognized by its black housing and the lack of a so-called "Magic Eye".

Scheme 1357

AGM BATTERY COMPONENTS DESCRIPTION CHART

Construction

The AGM battery differs from the conventional lead calcium battery as follows

1. larger plates: Larger plates allow a 25% larger power density.
2. Separators made of glass-fibre fleece: These can cause an up to 3-times higher cycle stability to be reached. This improves the cold starting capability, the power consumption and service life.
3. Airtight housing with pressure relief valve: The inspection plugs are sealed and can not be opened.
4. Battery acid bound in glass-fibre fleece: Battery acid is not found free in the housing as before, but is rather bound 100% in the glass-fibre fleece. This gives increased security against the acid escaping and thus reduces the environmental risk.

How it works

The AGM battery differs from conventional batteries in its non-polluting and substance-retaining behavior during charging.

When a vehicle battery is charged, the electrolysis process emits the gases oxygen and hydrogen.

1. In a conventional wet lead calcium battery, the two gases hydrogen and oxygen are dissipated into the atmosphere.
2. In an AGM battery, the two gases are converted back into water: The oxygen which is created at the positive electrode during charging passes through the permeable glass fibre fleece to the negative electrode. At the negative electrode the oxygen reacts with the arriving hydrogen ions in the electrolyte to form water (oxygen cycle).

In this manner, the gas, and thus the electrolyte, is not lost.

Only in the event of an excessively heavy build-up of gas, i.e. excessively high pressure build-up (20 to 200 mbar), does the pressure relief valve discharge the gas. In this process, the pressure relief valve does not allow any oxygen in the air to enter. Because the pressure in the battery is regulated by a valve, the AGM battery is also known as the VRLA battery (valve-regulated lead acid).

Notes for Service department

It is necessary when handling an AGM battery to observe some particular points pertaining to battery changing and installation location.

Charging

When charging removed batteries (so-called stand-alone batteries), do not exceed the maximum charging voltage of 15.2 V at room temperature. Also, for charging via positive battery connection point the maximum charging voltage of 15.2 volt at room temperature must not be exceeded. The batter can be damaged even with short charging of the AGM battery with a charging voltage higher than 15.2 volts. A charging voltage of more than 15.2 V is usually used in quick-charging routines.

Installation location

The AGM battery must not be installed in the engine compartment on account of the high spatial temperature differences, otherwise its service life will be significantly shortened.

Housing

On no account may AGM batteries be opened, as the ingress of oxygen from the atmosphere would cause the battery to lose its chemical balance, rendering it unserviceable.

Battery renewal

On principle any conventional lead-calcium battery can be replaced with an AGM battery. No changes result for the vehicle electrical system by using an AGM battery.

Note. AGM batteries are especially recommended for "problem customers".

"Problem customers" have a very high energy throughput through the battery. This high energy throughput is caused by stationary loads/consumers (TV, independent heating, etc.) and a bad use profile for the battery ("chauffeur operation", short-distance driving, "stop and go"). The use of an AGM battery is recommended for these problem customers.

Note. Important notes and instructions for handling batteries in the dealership can be found in: DISCONNECTING BATTERY BATTERY CHARGING EXTERNAL JUMP-STARTING AID

Battery care and maintenance

In low-maintenance batteries, check the acid level at least once a year. If necessary, top up with distilled water up to the top marking.

The increasing number of electronic control units in the car reduces the self-discharging time of the battery (even in standby mode). To maintain the battery service life and to avoid exhaustive discharging, recharge laid-up vehicles every 6 weeks at the latest. The time for self-discharging depends on vehicle type and equipment specification.

Battery test

The battery acid density can be used to measure the charge state. However this test produces uncertainty caused by a design-related range of variation. The acid density e.g. for a charged battery is 1.28 kg/l (in the tropical version the acid density is 1.23 kg/l).

Another interference factor is the acid lamination immediately after filling with distilled water.

Battery wear with partially sulfated and/or heavily contaminated plates will also lead to incorrect acid density test results.

61 20... Battery charge

If a normal or quick charger is used to charge the battery, the battery must be disconnected from the vehicle electrical system and removed. This prevents damage to paintwork and upholstery.

Ideally, battery charging is performed with BMW-approved charging computers

If necessary, open existing plugs on the individual cells.

61 20... Battery open-circuit current test

Note. Observe SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY .

Scheme 1358

The open-circuit current test is performed using the Diagnosis and Information System (DIS).

A vehicle battery is constructed for the installation location and the individual power requirements of the particular vehicle. These individual power requirements depend on the motorization and different types of optional equipment. The individually assigned vehicle battery is the ideal compromise between the power requirements of the vehicle electrical system and the weight and service life of the vehicle battery.

Vehicles with the automatic engine start-stop function or particular motorization and optional equipment are equipped with a special vehicle battery (AGM battery), since only this battery type can provide elevated power requirements over the extended service life. Installing a different vehicle battery can cause problems with vehicle electronics, can reduce functions or can cause leakage of battery acid.

In the event of an accident where the airbags are deployed in vehicles with a vehicle battery in the luggage compartment, the electrical connection between the vehicle battery and the trigger is automatically disconnected through pyrotechnics. This prevents a possible short circuit.

Proper operation of all of these safety and convenience functions requires a battery that conforms with specifications and that is properly registered in vehicles with energy management systems (IBS, power module).

Vehicles with energy management systems (IBS, power module): Register battery replacement

The vehicle electrical system is informed about the vehicle battery characteristic data, such as type, size, age and current power capacity. Therefore, only one work scope will be provided that is permitted by the current status of information.

When installing a new vehicle battery, the battery must be registered and thus must also be registered with the vehicle electrical system.

Diagnosis system

Register battery replacement

1. Service functions
2. Body
3. Voltage supply
4. Register battery replacement
5. Test plan

When retrofitting, a more powerful battery may be used. Standard batteries may always be replaced by AGM batteries with the same specifications.

When installing a battery of a different size or a different battery type, this change in vehicle data must be programmed into the vehicle data in accordance with specifications.

Programming system

1. Battery retrofitting

61 20 900 Disconnecting and connecting battery negative lead

Necessary preliminary tasks

1. «REMOVE BATTERY COVER OR OPEN RIGHT LUGGAGE COMPARTMENT TRIM PANEL»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-47-171-removing-and-installingreplacing)

Loosen nut (1).

Tightening torque 61 21 1AZ .

Disconnect battery negative lead (3) and secure at side.

Scheme 1359

Note. Do not connect the charger to the 12 V charging socket

The 12 V charging socket is supplied with voltage by the rear distribution box via relay. This relay drops out after terminal 15 OFF. This means that a trickle charger connected at the 12 V charging socket will be disconnected from the battery. Only charge the battery via the jump start terminal point. Only then can the voltage supply be registered by the vehicle.

1. Do not introduce any additional connections at the battery negative terminal.
2. Do not modify the grounding cable. The grounding cable also serves
3. dissipate heat.
4. Do not establish any connection between the IBS and the sensor screw.
5. 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.
6. Do not use IBS connections as levers.
7. Use a torque wrench and set tightening torque in accordance with repair instructions.
8. Do not release or tighten down sensor screw (screw with Torx head).
9. Avoid contact between IBS and ground.

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

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

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

12 00... Instructions for disconnecting and connecting battery

Observe SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY .

Before disconnecting battery

Turn off the ignition and other electrical loads/consumers to prevent sparking when reconnecting.

Note. If the ignition is not turned off when the battery is disconnected, fault memories may be set in some control units.

General notes on disconnecting battery

1. Do not disconnect battery leads and leads from alternator and starter motor while engine is running.
2. Cars with IBS on battery negative terminal: Do not under any circumstances pull/lever off pole shoes by force. Do not under any circumstances release socket-head cap screw of IBS.
3. Detach «TERMINAL OF BATTERY NEGATIVE»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-20-900-disconnecting-and-connecting) lead from car battery and second battery if fitted. Cover battery negative terminal(s) and secure.
4. When work is carried out on the electrical system, faults may be caused in the fault memories of some control units when the battery is connected.
5. When installing battery terminal: Tightening torque «61 21 1AZ»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-tightening-torques-e90) .

After connecting battery

For example

1. Vehicles with «AUTOMATIC ENGINE START-STOP FUNCTION (MSA)»(/bmw/m3/e90-2007-2013/remont/oem-general-information/#maintenance-and-general-information-repair-e90__00-safety-information-for-working-on)
2. If necessary, carry out «ADJUSTMENT FOR ACTIVE FRONT STEERING»(/bmw/m3/e90-2007-2013/remont/manual-power-steering/#steering-and-wheel-alignment-repair-e90)
3. If necessary, activate slide/tilt sunroof . See «54 0... NOTES ON GLASS SLIDE/TILT SUNROOF (INITIALIZATION/NORMAL OF CHARACTERISTIC CURVE)»(/bmw/m3/e90-2007-2013/remont/sun-rooft-topconvertible-top/#slidetilt-roof-repair-e90__54-0-notes-on-glass-slidetilt) .
4. If necessary, activate power windows . See «6762... NOTES ON INITIALIZING POWER WINDOW UNIT IN FRONT DOOR»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#electrical-drives-repair-e90__67-62-notes-on-initializing-power) or «6762... NOTES ON INITIALIZING POWER WINDOW UNIT IN FRONT DOOR»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#electrical-drives-repair-e90__67-62-notes-on-initializing-power) .
5. If necessary, activate «MIRROR WITH COMPASS»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-16-calibrating-compass-in-inside) .

Vehicles with a two battery system

Starter and system battery

A two-battery system has a starter battery circuit and a system battery circuit. An auxiliary control unit monitors both battery circuits. Depending on the situation, the battery circuits are connected to or isolated from the auxiliary control unit via an cut-off relay.

Two AGM batteries, whose design and properties are described in AGM BATTERIES , are used as a storage battery.

Receiving/giving starting aid via jump start terminal point

The engine can be jump-started with an external voltage supply via the jump start terminal on the right side of the engine compartment.

Note. The starter battery is isolated from the alternators when the engine hood/bonnet is open.

Giving starting assistance via the jump start terminal is thus limited by the capacity of the starter battery when the engine hood/bonnet is open.

Charging starter and system batteries via jump start terminal point

The starter battery is charged as a matter of priority with a charger connected to the jump start terminal. The voltage at the starter battery is the decisive factor in determining whether the system battery is also included in the charging operation. The auxiliary control unit automatically detects a charging operation at a charging voltage at the starter battery of > or = 13.5 V. The cut-off relay is closed and thus the system battery is connected in parallel. Both batteries are now charged.

Prerequisite

1. Terminal 61 inactive
2. Terminal 15 inactive

If terminal 15 becomes "active" during the charging operation, the cut-off relay is opened immediately and again only the starter battery is charged.

Note. When the engine hood is open, the cut-off relay is also opened in normal operation when the engine is running. A special mode can be set by means of diagnosis for workshop/garage operation. The cut-off relay is closed from terminal R in this operating mode. This mode is automatically reset once a distance of 5 km has been driven.

Trickle charging

The increased standby current consumption can be compensated for via the jump-start connection point with the aid of the "Acctiva easy" battery trickle charger.

Do not start the engine with help of starting sprays.

Preparation

Conform with the following when starting the engine with a jump starting cable.

1. Ensure that the jump starting cable wires are of appropriate cross-section size.
2. Only use fuse-protected jump starting cables.
3. Check whether the current-supplying battery has 12 V voltage.
4. If the engine is started from the battery of another vehicle, ensure that there is no contact between the bodies of both vehicles.

If the battery in the vehicle supplying power is weak, start the engine of this vehicle and let it run at idling speed.

Operation

It is essential to conform to the procedures so as to avoid injury to persons or damage to parts.

1. Automatic transmission: select drive position "P", apply parking brake.
2. Manual transmission: move gear lever to neutral position, apply parking brake.
3. Ensure that the jump leads cannot get caught in rotating parts, e.g. fan.
4. First connect both positive poles of the batteries with one jump starting cable (red).
5. Use the battery positive terminal in the engine compartment for vehicles with the battery in the luggage compartment.
6. Then use the second jump starting cable (black) to connect the negative post of the current-supplying battery with the earth/ground point (not the negative pole or the body) of the vehicle to be started.

Risk of explosion!

After the engine of the vehicle to be started has fired, first disconnect the jump starting cable between the negative pole and the earth/ground point. Then remove the starting cable from the positive poles.

The following steps must be carried out for a "power reset"

1. Switch off and disconnect battery charger
2. Switch off ignition Cars with ignition key: Turn ignition key to 0 position Cars with identification sensor: Remove identification sensor from slot Cars with comfort access system: Make sure terminal is in 0 position
3. Disconnect battery negative terminal
4. Reconnect battery negative terminal (to ensure bus activity)
5. Waiting time (5-10 seconds)
6. Disconnect battery negative terminal
7. Waiting time (1 minute)
8. Connect battery negative terminal and tighten, tightening torque «61 21 1AZ»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-tightening-torques-e90)
9. Connect and switch on battery charger
10. Switch ignition on

Safety regulations

Safety regulations for HANDLING COMPONENTS OF AIRBAG SYSTEM .

INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .

Procedure for cable repair

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 .

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 or smoking!

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!).

61 20 005 Testing battery with battery tester

Necessary preliminary tasks

Remove LUGGAGE COMPARTMENT FLOOR TRIM PANEL .

Note. Use BMW-recommended battery tester* to test the battery.

*Sourcing reference BMW Workshop Equipment Catalogue

Procedure

1. Turn off ignition and close doors
2. Connect battery tester directly to battery terminals
3. Select Battery test and confirm
4. Enter vehicle identification number
5. Enter battery data
6. Carry out battery test

Scheme 1360

61 20... Threshold values for battery inspection of all battery (telephone except for telephone battery)

SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY.

BATTERY CHARGE STATUS - BEFORE CHARGING BATTERY

BATTERY CHARGE STATUS - AFTER CHARGING BATTERY

1. Charge condition and starting power must always be evaluated together
2. When test charging for more than 5 hours, use charger Gossen CG 32 or Siemens/Gossen VB 801
3. Fully charge until charge state is more than 80 %.

Note. If battery was checked on the positive terminal in the engine compartment, repeat check directly on battery for sake of safety.

61 20 503 Vehicle battery - closed-circuit current monitoring

To access negative lead of battery, perform the necessary preliminary work described in DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD .

Do not disconnect negative lead of battery.

Connect BMW diagnosis system.

Connect clip-on probe to negative lead of battery. The arrow on the current clamp must point towards the battery.

Measure closed-circuit current.

After RECONNECTING the vehicle battery, carry out the following procedure for setting the steering angle

1. Start engine.
2. Turn steering wheel left to full lock.
3. Turn steering wheel right to full lock.
4. Turn steering wheel to central position.
5. Turn off engine.
6. Turn on ignition (terminal 15), AFS telltale and Check Control message go out.

Note. Entry in the fault memory remains unaffected by this procedure, therefore if necessary: Connect diagnosis system Clear fault memory

Necessary preliminary tasks

1. «REMOVE BATTERY COVER OR OPEN RIGHT LUGGAGE COMPARTMENT TRIM PANEL»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-47-171-removing-and-installingreplacing)

Loosen nut (1).

Tightening torque 61 21 1AZ .

Disconnect battery negative lead (3) and secure at side.

The following steps must be carried out for a "power reset"

1. Switch off and disconnect battery charger
2. Switch off ignition Cars with ignition key: Turn ignition key to 0 position Cars with identification sensor: Remove identification sensor from slot Cars with comfort access system: Make sure terminal is in 0 position
3. Disconnect battery negative terminal
4. Reconnect battery negative terminal (to ensure bus activity)
5. Waiting time (5-10 seconds)
6. Disconnect battery negative terminal
7. Waiting time (1 minute)
8. Connect battery negative terminal and tighten, tightening torque «61 21 1AZ»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-tightening-torques-e90)
9. Connect and switch on battery charger
10. Switch ignition on

61 21 010 Removing and installing or replacing battery

To ensure the correct safety and convenience functions, install only the original battery (battery size and type) stored in the vehicle order. OBSERVE NOTE ON BATTERY REPLACEMENT .

Necessary preliminary tasks

1. Remove «FLAP»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-47-171-removing-and-installingreplacing) in luggage compartment panel on right
2. Disconnect «BATTERY NEGATIVE LEAD»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-20-900-disconnecting-and-connecting)
3. Remove «DISTRIBUTION BOX»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-14-010-removing-and-installingreplacing)

Unlock positive terminal cover (1) and remove.

Scheme 1361

Detach vent (1) in direction of arrow.

Release nut (6) of safety battery terminal (2).

Tightening torque 61 21 1AZ .

Detach safety battery terminal (2) towards top, lay to one side and secure.

Release threaded pin (5) and remove holder with battery crash element (4).

Fold back both bar fasteners (3) and pull battery towards rear out of associated fixture.

Lift out battery.

Scheme 1362

Installation

Make sure battery is correctly seated in associated fixture.

Replacement

1. Read out fault memory, clear if necessary
2. On vehicles with IBS (intelligent battery sensor) «REGISTER BATTERY REPLACEMENT»(/bmw/m3/e90-2007-2013/remont/gauges-instrument-panels/#engine-electrical-system-repair-e90__61-20-battery-replacement-information)

Note. DC/DC converter in vehicles with automatic start-stop function.

There are two versions

1. Without additional bracket for diesel engine vehicles
2. With additional bracket for gasoline engine vehicles

Depending on the equipment, one or both versions are installed in the M3

Necessary preliminary work

Remove lower section of microfilter housing (all except M3)

Remove RIGHT UPPER SECTION OF MICROFILTER HOUSING M3

Unlock fasteners (1) from below and slide upwards approx. 10 mm.

Unlock locks (2) in direction of arrow.

Remove cover (3).

Diesel engine vehicles (without additional bracket)

Release lugs in direction of arrow. Remove DC/DC converter (1) by pulling upward. Disconnect plug connection (2).

Gasoline engine vehicles (with additional bracket)

Release lugs in direction of arrow. Remove DC/DC converter (1) by pulling upward. Disconnect plug connection (2).

M3

Release tabs in direction of arrow and remove DC/DC converter with additional bracket (1) upward. Disconnect plug connection (2).

Release tabs in direction of arrow and remove DC/DC converter without additional bracket (3) upward. Disconnect plug connection (4).

61 30 020 Removing and installing/replacing switch block (M3)

Necessary preliminary tasks

1. Remove «TRIM FOR STORAGE TRAY»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-16-212-removing-and-installing)

If necessary, remove socket housing (1) from holder (2).

Unlock catches (3) and feed switch block (4) in direction of arrow out of storage compartment trim (5).

Installation

Make sure switch block catch (4) engages correctly in storage compartment trim (5).

If necessary, make sure socket housing (1) is correctly seated in holder (2).

Scheme 1363

61 31 996 Carrying out steering angle sensor adjustment

Note. Steering angle sensor adjustment must be carried out: Before adjustment work on the front axle/steering after all mechanical work on the steering system E46 (all-wheel drive), E53, E83: after disconnecting the battery after replacement/coding/programming of the following components: Fixture for switches of steering column/switch cluster/steering angle sensor Dynamic Stability Control (DSC) control unit Control unit active anti-roll stabilization (ARS)

Connect vehicle to BMW diagnosis system or Software Service Station. Select and carry out steering angle sensor adjustment under Service functions.

Scheme 1364

61 31 195 Removing and installing (replacing) front controller (from 09/2008)

Note. The number of buttons and shape of controller can vary depending on vehicle type.

Before LCI: Controller (1) has buttons on bottom only.

After LCI: Controller (2) has buttons top and bottom.

Scheme 1365

Note. These repair instructions describe the removal and installation (replacement) of controller (2)!

Necessary preliminary tasks

1. Remove «TRIM FOR STORAGE TRAY»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-16-212-removing-and-installing)

Carefully raise catches (1) on controller holder (3) and remove controller (2) towards top.

Installation

Make sure controller (2) is correctly engaged in controller holder (3).

Scheme 1366

Replacement

Carry out vehicle programming and encoding.

6Foto1 31 038 Removing and installing (replacing) switch for passenger airbag deactivation

Necessary preliminary tasks

1. Disconnect «BATTERY NEGATIVE LEAD»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-20-900-disconnecting-and-connecting)
2. «REMOVE SIDE COVER ON INSTRUMENT PANEL»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-45-replacing-side-cover-on)

Unlock catches (1) and feed out switch for passenger airbag deactivation (2) to front of cover.

Scheme 1367

Installation

Make sure switch for passenger airbag deactivation (2) is correctly seated in cover.

Installation instructions for replacement only for E63/E64 with production date up to 01/2010

A groove must be filed in the trim at location (1).

Scheme 1368

Replacement

Remove LOCK CYLINDER FOR PASSENGER AIRBAG DEACTIVATION .

61 31 122 Removing and installing/replacing tow hitch switch

Necessary preliminary tasks

1. Open flap in luggage compartment panel on left

Release screw (1).

Disconnect plug connection underneath and remove tow hitch switch (2).

Scheme 1369

61 31 043 Removing and installing or replacing roof switch cluster

Carefully unclip trim of interior roof light (1) from interior roof light with special tool 00 9 341 in direction of arrow and remove.

Scheme 1370

Note. Roof switch cluster is secured to frame of headliner (2) with two retaining clips (1).

Scheme 1371

Retaining clips (1) are located on centerline of both reading lights.

Position special tool 00 9 341 as illustrated.

Scheme 1372

Note. Shown from above on a model for clearer illustration.

Position special tool 00 9 341 as illustrated.

Scheme 1373

Position special tool 00 9 341 as illustrated and release retaining clips (1).

Note. Only then can the roof switch cluster be removed without causing damage!

Scheme 1374

Lever roof switch cluster (1) out of headliner (2) with special tool 00 9 341 in direction of arrow.

Disconnect plug connections underneath and remove roof switch cluster (1).

Note. Disconnecting the plug connection for the hands-free microphone or emergency call button results in fault memory entries in the telephone control unit (limitation in the emergency call system).

Scheme 1375

After fitting, read out fault memory and if necessary delete entries.

Installation note

Immediately after removal, fit interior roof light cover (1) to roof switch cluster (3)

1. Feed in interior roof light cover (1) at line (2)
2. Press interior roof light cover (1) onto interior roof light in direction of arrow

Make sure interior roof light cover (1) is correctly engaged on interior roof light.

Scheme 1376

Installation note

If necessary, initialize SLIDE/TILT SUNROOF .

Replacement

1. Carry out vehicle programming and encoding
2. Initialize «SLIDE/TILT SUNROOF»(/bmw/m3/e90-2007-2013/remont/sun-rooft-topconvertible-top/#slidetilt-roof-repair-e90__54-0-notes-on-glass-slidetilt) ..
3. If necessary, remove «BULBS»(/bmw/m3/e90-2007-2013/remont/exterior-lights/#lights-repair-e90__63-99-431-replacing-bulb-for) .

61 31 133 Removing and installing/replacing AV connection socket

Note. Version with rear air conditioning is shown.

Scheme 1377

Installation

Catches (1 and 3) and guides (2) must not be damaged.

Scheme 1378

Lever AV connection socket (1) with a suitable tool (2) upwards out of storage compartment (3).

Scheme 1379

Disconnect plug connection (1).

Remove AV connection socket (2) upwards out of storage compartment (3).

Installation

Locks (4) must not be damaged.

Make AV connection socket (1) is correctly seated in storage compartment (3).

Scheme 1380

Note. DC/DC converter in vehicles with automatic start-stop function. There are two versions: Without additional bracket for diesel engine vehicles With additional bracket for gasoline engine vehicles

Depending on the equipment, one or both versions are installed in the M3

Necessary preliminary work

Remove lower section of microfilter housing (all except M3)

Remove right upper section of MICROFILTER HOUSING M3

Unlock fasteners (1) from below and slide upwards approx. 10 mm.

Unlock locks (2) in direction of arrow.

Remove cover (3).

Diesel engine vehicles (without additional bracket)

Release lugs in direction of arrow.

Remove DC/DC converter (1) by pulling upward. Disconnect plug connection (2).

Gasoline engine vehicles (with additional bracket)

Release lugs in direction of arrow.

Remove DC/DC converter (1) by pulling upward. Disconnect plug connection (2).

M3

Release tabs in direction of arrow and remove DC/DC converter with additional bracket (1) upward. Disconnect plug connection (2).

Release tabs in direction of arrow and remove DC/DC converter without additional bracket (3) upward.

Disconnect plug connection (4).

61 31 194 Removing and installing/replacing Drivelogic button (M3)

Necessary preliminary tasks

1. Remove «TRIM FOR STORAGE COMPARTMENT»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-16-212-removing-and-installing)

Unlock catches (1) with a suitable tool.

Remove Drivelogic button (2) in direction of arrow from storage compartment trim (3).

Installation

Make sure Drivelogic button (2) is correctly seated on storage compartment trim (3).

Scheme 1381

61 31 023 Removing and installing/replacing Start/Stop switch

Necessary preliminary tasks

1. Remove «DECORATIVE STRIP ON INSTRUMENT PANEL ON RIGHT»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-45-380-removing-and-installing)

Press catches (1) together and unclip Start/Stop switch (2) in direction of arrow.

Scheme 1382

Operation is described in

Removing and installing/replacing AV CONNECTION SOCKET

61 31 229 Removing and installing/replacing both switches on sport steering wheel

Necessary preliminary tasks

1. Remove «AIRBAG UNIT»(/bmw/m3/e90-2007-2013/remont/manual-power-steering/#steering-and-wheel-alignment-repair-e90__32-34-030-removing-and-installingreplacing)

Note. Illustrations show multifunction steering wheel (4) removed.

Release screws (1).

Detach decorative trim (3) in direction of arrow from holders (2).

Disconnect associated plug connection and remove complete decorative trim (3).

Scheme 1383

Installation

Make sure electrical leads are correctly routed.

Feed wiring harness (4) out of associated holders.

Release screws (1) and remove both multifunction steering wheel switches (2) from decorative trim (3).

Installation

Make sure there is a uniform gap between both multifunction steering wheel switches (2) and decorative trim (3).

Scheme 1384

61 31 054 Removing and installing/replacing center console control panel (with CCC/ASK, CIC)

A hard disk is installed in the Car Information Computer (CIC).

Carry out mechanical work on the CIC and adjacent components with care.

Avoid subjecting the CIC to vibration/shocks.

Necessary preliminary work

1. Remove «DECORATIVE STRIP ON INSTRUMENT PANEL ON RIGHT»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-45-380-removing-and-installing)
2. Remove «CONTROL PANEL FOR HEATING - A/C SYSTEM»(/bmw/m3/e90-2007-2013/remont/automatic-hvac-system/#heating-and-air-conditioning-repair-e90__64-11-378-removing-and-installingreplacing)

Unclip trim (3) at fastening points (1) and (2).

Feed out associated ribbon cable and remove trim (3) complete with center console control panel (4).

Scheme 1385

Replacement

Unclip center console control panel (1) at fastening points (2) and (4) and remove.

Note. Ribbon cable (3) of center console control panel (1) leads to heating - A/C system control panel.

Scheme 1386

Installation note

Make sure center console control panel (1) engages correctly in upper fastening points (4) and lower fastening points (2).

Replacement

Assign buttons according to vehicle equipment.

Note. LEDs for seat heating must be removed from the center console switch cluster on vehicles build after 09/2009 with automatic climate control and seat heating!

Refer to information on ESD prevention!

Undo screws (see arrows) and detach cover (1).

Tightening torque: 0.3 Nm

To tighten screws, use special tool 00 9 450 .

Scheme 1387

Remove pc-board together with ribbon cable (1) from casing (2).

Scheme 1388

Note. A total of 6 LEDs (1) are removed.

Scheme 1389

Grip LED (1) with suitable pliers (2) as illustrated. Turn pliers (2) in clockwise direction.

Repeat procedure for remaining LEDs.

Installation note

Make sure the center console switch cluster is reassembled correctly!

Scheme 1390

61 31 052 Removing and installing/replacing center console switch cluster (without CCC/ASK)

Necessary preliminary work

1. Remove «CONTROL PANEL FOR HEATER/AIR CONDITIONING SYSTEM»(/bmw/m3/e90-2007-2013/remont/automatic-hvac-system/#heating-and-air-conditioning-repair-e90__64-11-377-removing-and-installingreplacing)

Replacement

Unfasten plug connection (1) and disconnect.

Unclip center console switch cluster (2) at retaining points (4).

Remove center console switch cluster (2) in direction of arrow from trim (3).

Assign buttons according to vehicle equipment.

Scheme 1391

Replacement note!

Excess length of ribbon cable!

To avoid damage and rattling noise, the ribbon cable must be fitted and secured correctly!

Installation note

Replacement on vehicles with control panel for automatic climate control

Install ribbon cable (1) as illustrated and secure over a wide area (A) with adhesive tape (2). Use the entire length of the side face (B) of the center console switch cluster (3) for this purpose.

Scheme 1392

Refer to INFORMATION ON SECURING COMPONENTS WITH ADHESIVE TAPE .

Installation note

Replacement on vehicles with control panel for air conditioning system

Install ribbon cable (1) as illustrated and secure with two adhesive strips (2).

Cleanly cut off adhesive strips (2).

Refer to INFORMATION ON SECURING COMPONENTS WITH ADHESIVE TAPE .

Scheme 1393

Note. LEDs for seat heating must be removed from the center console switch cluster on vehicles build after 09/2009 with automatic climate control and seat heating!

Refer to information on ESD prevention!

Undo screws (see arrows) and detach cover (1).

Tightening torque: 0.3 Nm

To tighten screws, use special tool 00 9 450 .

Remove pc-board together with ribbon cable (1) from casing (2).

Note. A total of 6 LEDs (1) are removed.

Grip LED (1) with suitable pliers (2) as illustrated. Turn pliers (2) in clockwise direction.

Repeat procedure for remaining LEDs.

Installation note

Make sure the center console switch cluster is reassembled correctly!

61 31 299 Removing and installing/replacing clutch switch module

Necessary preliminary tasks

1. Remove «TRIM PANEL FOR PEDAL ASSEMBLY»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-45-185-removing-and-installingreplacing) .

Note. Clutch master cylinder (2) is removed for purposes of clarity.

Lever out clutch switch module (1) from clutch master cylinder (2) with screwdriver.

Unlock plug (4) and disconnect from housing (3).

Scheme 1394

Installation

Clutch switch module is secured against incorrect installation.

Clutch switch module must snap audibly into place.

Scheme 1395

61 31 006 Removing and installing/replacing fixture for steering column stalk

Necessary preliminary tasks

1. Remove «STEERING WHEEL»(/bmw/m3/e90-2007-2013/remont/manual-power-steering/#steering-and-wheel-alignment-repair-e90__32-33-010-removing-and-installingreplacing)
2. Remove «TOP SECTION OF STEERING COLUMN CASING»(/bmw/m3/e90-2007-2013/remont/manual-power-steering/#steering-and-wheel-alignment-repair-e90__32-31-003-removing-and-installingreplacing) .
3. Remove «LOWER SECTION OF STEERING COLUMN TRIM»(/bmw/m3/e90-2007-2013/remont/manual-power-steering/#steering-and-wheel-alignment-repair-e90__32-31-020-removing-and-installingreplacing)

Release screws (1).

Pull back fixture for steering column switch (2) in direction of arrow.

Disconnect plug connections behind and remove fixture for steering column stalk (2).

Installation

Carry out STEERING ANGLE SENSOR ADJUSTMENT .

On vehicles with active front steering, steering angle sensor adjustment is performed by means of INITIAL OPERATION /adjustment of active front steering.

Scheme 1396

Replacement

1. Remove «VOLUTE SPRING CASSETTE»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-31-011-removing-and-installingreplacing)
2. Carry out vehicle programming and encoding. NOTE: If replacement of the steering column switch cluster is initiated via Progman, the steering column switch cluster is coded indirectly via the DSC control unit If coding is cancelled, first adjust the steering angle sensor; this makes a brand-new steering column switch cluster coding-compatible again if necessary Then code the DSC control unit again
3. Carry out «STEERING ANGLE SENSOR ADJUSTMENT»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-31-996-carrying-out-steering) NOTE: If steering angle sensor adjustment is cancelled, first code the DSC control unit Then adjust the steering angle sensor again
4. Vehicles with active front steering: Steering angle sensor adjustment is performed by means of «INITIAL OPERATION/ADJUSTMENT»(/bmw/m3/e90-2007-2013/remont/manual-power-steering/#steering-and-wheel-alignment-repair-e90__32-10-005-adjustment-for-active) of active front steering If necessary, proceed in accordance with instructions

61 31 342 Removing and installing/replacing gear selector switch (twin clutch transmission)

Necessary preliminary tasks

1. Disconnect «BATTERY NEGATIVE LEAD»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-20-900-disconnecting-and-connecting)
2. Remove «PARKING LOCK CABLE FROM TRANSMISSION»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-00-001-removing-and-installing)
3. Remove «TRIM FOR STORAGE COMPARTMENT»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-16-212-removing-and-installing)

Disconnect plug connection (1).

Replacement

Disconnect plug connection (2).

Remove SHIFT LEVER KNOB FOR TWIN CLUTCH TRANSMISSION (3) .

Scheme 1397

Release screws (1). Tightening torque 61 31 6AZ .

Feed gear complete gear selector switch (4) with cable and rubber seal (2) upwards out of center console (5).

Scheme 1398

Installation

Make sure rubber seal (2) is correctly fitted. Retaining lugs (3) of gear selector switch (4) must be positioned in associated openings in rubber seal (2). Feed in rubber seal (2) between center console (5) and carpet (6).

Replacement

Carry out vehicle programming and encoding.

61 31 131 Removing and installing/replacing left or right shift paddle for transmission (twin clutch transmission) (M3)

Necessary preliminary tasks

1. Remove «AIRBAG UNIT»(/bmw/m3/e90-2007-2013/remont/manual-power-steering/#steering-and-wheel-alignment-repair-e90__32-34-030-removing-and-installingreplacing)

Disconnect plug connection (1).

Release screw (3).

Feed out wiring harness (2) and remove shift paddle for transmission (5) in direction of arrow from steering wheel (4).

Scheme 1399

Installation

Make sure shift paddle

for transmission (5) is correctly seated on steering wheel (4)

Make sure wiring harness (2) is laid correctly.

61 31 037 Removing and installing/replacing light control unit

Necessary preliminary tasks

1. Remove «DECORATIVE STRIP ON INSTRUMENT PANEL ON LEFT»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-45-370-removing-and-installing)

Lever out trim of light control unit (2) with special tool 00 9 317 WEDGE at fastening points (1) and pull back in direction of arrow.

Unlock and disconnect associated plug connection, remove trim of light control unit (2).

Scheme 1400

Replacement

Unlock catches (1) and unclip light control unit (2) from trim (3).

Scheme 1401

61 31... Removing and installing/replacing parking lock from series status 09/2008

Necessary preliminary tasks

1. Remove gear selector switch
2. Remove «PARKING LOCK CABLE FROM TRANSMISSION»(/bmw/m3/e90-2007-2013/remont/automatic-trans/#double-clutch-gearbox-repair__28-00-001-removing-and-installing)

Release screws (1).

Feed rubber seal (2) completely out of gear selector switch (3).

Release parking lock (4) at points (5) and remove in direction of arrow.

Installation

Make sure parking lock (4) is exactly seated on gear selector switch (3).

Make sure rubber seal (2) is correctly seated.

Scheme 1402

Install gear selector switch (1).

Install PARKING LOCK CABLE ON TRANSMISSION .

Installation

Make sure rubber seal is correctly seated.

Scheme 1403

Release handle (1) from gear selector switch (2).

Withdraw transportation lock (3) from parking lock (4).

US version only

Transmission emergency release (5) is provided with a grey cap.

Scheme 1404

61 31 241 Removing and installing/replacing right hood/bonnet contact switch (M3)

Lever bonnet/hood contact switch (1) with special tool 641020 out of microfilter housing upper section (2).

Disconnect plug connection (3) and remove bonnet/hood contact switch (1).

Scheme 1405

Installation

Make sure bonnet/hood contact switch (1) is correctly seated in microfilter housing upper section (2).

61 31 008 Removing and installing/replacing steering-column switch cluster

Necessary preliminary work

1. Remove steering wheel
2. Remove «STEERING COLUMN SHROUD LOWER SECTION»(/bmw/m3/e90-2007-2013/remont/manual-power-steering/#steering-and-wheel-alignment-repair-e90__32-31-020-removing-and-installingreplacing)
3. If necessary, remove switch for steering column adjustment

Note. The COIL SPRING CASSETTE (1) may be replaced separately, if necessary!

Scheme 1406

Disconnect plug connection (1).

Scheme 1407

Release screws (1).

Tightening torque 61 31 8AZ .

Remove steering-column switch cluster in direction of arrow.

Scheme 1408

Installation note

The steering column switch cluster is installed in reverse sequence.

Carry out steering angle sensor adjustment.

Replacement

1. Remove volute spring cassette
2. Carry out vehicle programming and encoding NOTE: If replacement of the steering column switch cluster is initiated via Progman, the steering column switch cluster is coded indirectly via the DSC control unit If coding is cancelled, first adjust the steering angle sensor; this makes a brand-new steering-column switch cluster coding-compatible again if necessary Then code the DSC control unit again
3. Carry out steering angle sensor adjustment NOTE: If steering angle sensor adjustment is cancelled, first code the DSC control unit Then adjust the steering angle sensor again
4. Vehicles with active steering: Steering angle sensor is adjusted by means of «INITIAL OPERATION/ADJUSTMENT»(/bmw/m3/e90-2007-2013/remont/manual-power-steering/#steering-and-wheel-alignment-repair-e90__32-10-005-adjustment-for-active) of active front steering If necessary, proceed in accordance with instructions

61 31 101 Removing and installing/replacing switch for backrest width adjustment

Necessary preliminary tasks

1. Remove outer cover See «REMOVING AND INSTALLING/REPLACING OUTER COVER ON LEFT OR RIGHT FRONT SEAT BACKREST»(/bmw/m3/e90-2007-2013/remont/seats/#seats-repair-e90__52-13-040-removing-and-installingreplacing) or «REMOVING AND INSTALLING/REPLACING OUTER COVER ON FRONT LEFT OR RIGHT SEAT (NORMAL)»(/bmw/m3/e90-2007-2013/remont/seats/#seats-repair-e90__52-14-040-removing-and-installingreplacing) on front seat

Disconnect plug connection (1).

Unlock retaining tab (2) in direction of arrow.

Remove switch for backrest width adjustment (3) in direction of arrow.

Scheme 1409

61 31 079 Removing and installing/replacing switch for hazard warning flashers/central locking

Necessary preliminary tasks

1. Remove «DECORATIVE STRIP ON INSTRUMENT PANEL ON RIGHT»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-45-380-removing-and-installing)

Unclip switch for hazard warning flashers/central locking (1) in direction of arrow from right instrument panel decorative strip (2).

Scheme 1410

61 31 208 Removing and installing/replacing switch for lumbar support

Necessary preliminary tasks

1. Remove outer cover See «REMOVING AND INSTALLING/REPLACING OUTER COVER ON LEFT OR RIGHT FRONT SEAT BACKREST»(/bmw/m3/e90-2007-2013/remont/seats/#seats-repair-e90__52-13-040-removing-and-installingreplacing) or «REMOVING AND INSTALLING/REPLACING OUTER COVER ON FRONT LEFT OR RIGHT SEAT (NORMAL)»(/bmw/m3/e90-2007-2013/remont/seats/#seats-repair-e90__52-14-040-removing-and-installingreplacing) on front seat

Disconnect plug connection (3).

Unlock catches (1).

Remove switch for lumbar support (2) in direction of arrow.

Scheme 1411

61 31 083 Removing and installing/replacing switch for unlocking rear lid

Note. To facilitate handling, unclip OBD socket cover (1).

Unclip rear lid unlocking switch (2) in direction of arrow.

Disconnect associated plug connection and remove switch for unlocking rear lid (2).

Scheme 1412

61 31 011 Removing and installing/replacing volute spring cassette

Necessary preliminary tasks

1. Remove «FIXTURE FOR STEERING COLUMN STALK»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-31-006-removing-and-installingreplacing)

Unlock catches (1).

Press lock (2) and remove volute spring cassette (4) in direction of arrow from fixture for steering column stalk (3).

Scheme 1413

Scheme 1414

Installation

Notch (3) on ring (1) must line up with arrow (4) on switch (2).

Scheme 1415

61 31 009 Repairing steering column switch cluster (SZL)

Necessary preliminary tasks

1. Remove «VOLUTE SPRING CASSETTE»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-31-011-removing-and-installingreplacing)
2. Spread antistatic mat
3. Use antistatic wrist trap with connecting line

Note on ordering

1. Workshop equipment
2. Workshop equipment catalogue
3. Order number

61 31 9 141 875

Note. Installation is described separately.

Removal

Scheme 1416

1. Unlock retaining lugs on upper housing section (1) with a suitable tool.
2. Remove upper housing section.
3. Release screws (1) in optical element (2).

Note. After removal, render optical element unusable and dispose of it in the appropriate manner.

Scheme 1417

Scheme 1418

Unclip encoded disc (1) from rear of steering column switch cluster with plastic tube (2) supplied for the purpose.

In this process, hold encoded disc by inserting two fingers in the hole.

Scheme 1419

To prevent damage, tilt encoded disc (1) away from the printed circuit board when removing.

Apply grease supplied for the purpose to friction face (1) of bearing race of front of steering column switch cluster.

Scheme 1420

Installation

Scheme 1421

1. Do not touch encoded disc (1) with your fingers!
2. Do not touch printed circuit board (2)!
3. Do not apply pressure to encoded disc (3)!
4. Do not touch sides of encoded disc (4)!
5. Hold encoded disc (1) by inserting two fingers in the hole.
6. Position encoded disc centered in fixture and clip it in.
7. Turn encoded disc to and front to spread the grease over the friction face

Scheme 1422

Scheme 1423

Assembly optical element (1) from individual parts included in the repair kit.

1. Secure optical element (2) with screws (1).
2. Tightening torque: 0.26 Nm.
3. Clip upper housing section (1) into place.
4. After inserting coil spring cassette, affix "CDS" label close to part-number label (2).

Installation note

Make sure retaining lugs are correctly engaged.

Scheme 1424

Installation note

Mark (1) and mark (2) must point to each other.

Scheme 1425

Carry out STEERING ANGLE SENSOR ADJUSTMENT .

Carry out vehicle programming and encoding.

61 31 310 Replacing brake light switch

Necessary preliminary tasks

1. Remove «TRIM PANEL FOR PEDAL ASSEMBLY»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-45-185-removing-and-installingreplacing) .

Unfasten plug connection (1) and disconnect.

Pull brake light switch (2) in direction of arrow out of brake light switch holder (3).

Installation

1. Press brake pedal (4) to floor.
2. Slide brake light switch (2) as far as it will go into brake light switch holder (3).
3. Grip brake light switch holder (3), slowly return brake pedal (4) to starting position and pull back to stop.

Scheme 1426

Note. Removing brake light switch holder (2)

Press brake pedal.

Press catches (1) together and unclip brake light switch holder (2) from bearing block (3).

Scheme 1427

61 31 382 Replacing coolant level switch

Necessary preliminary tasks

1. If necessary, release screws for «COOLANT EXPANSION TANK»(/bmw/m3/e90-2007-2013/remont/cooling-system-mechanical/#cooling-system-repair-e90__17-11-100-removing-and-installingreplacing) and raise coolant expansion tank slightly

Note. Operation is shown by way of example on the E85. There may be differences in detail in the case of other vehicle models.

Disconnect plug connection (1).

Turn coolant level switch (2) in direction of arrow and feed downwards out of coolant expansion tank (3).

Scheme 1428

Necessary preliminary tasks

1. If necessary, release screws for «COOLANT EXPANSION TANK»(/bmw/m3/e90-2007-2013/remont/cooling-system-mechanical/#cooling-system-repair-e90__17-11-100-removing-and-installingreplacing) and raise coolant expansion tank slightly

Note. Operation is shown by way of example on the E85. There may be differences in detail in the case of other vehicle models.

Disconnect plug connection (1).

Turn coolant level switch (2) in direction of arrow and feed downwards out of coolant expansion tank (3).

Necessary preliminary tasks

1. If necessary, release screws for «COOLANT EXPANSION TANK»(/bmw/m3/e90-2007-2013/remont/cooling-system-mechanical/#cooling-system-repair-e90__17-11-100-removing-and-installingreplacing) and raise coolant expansion tank slightly

Note. Operation is shown by way of example on the E85. There may be differences in detail in the case of other vehicle models.

Disconnect plug connection (1).

Turn coolant level switch (2) in direction of arrow and feed downwards out of coolant expansion tank (3).

61 31 492 Replacing level switch for windscreen washer system

Necessary preliminary tasks

1. Release «FLUID RESERVOIR FOR WINDSCREEN WASHER SYSTEM»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-71-061-replacing-washer-fluid) and pull out

Disconnect plug connection (1).

Turn level switch for windscreen washer system (2) in direction of arrow and remove towards bottom from fluid reservoir for windscreen washer system (3).

Scheme 1429

61 31 115 Replacing rocker switch for side window operation (front)

Driver's side

Lever rocker switch for side window operation (1) with special tool 00 9 341 at highlighted points (2) out of armrest (3).

Disconnect associated plug connection and remove rocker switch for side window operation (1).

Scheme 1430

Installation

Retaining clips (1) of rocker switch for side window operation (2) must not be damaged or missing.

Make sure rocker switch for side window operation (2) is correctly seated in armrest.

Scheme 1431

Passenger side

Lever rocker switch for side window operation (1) with special tool 00 9 317 WEDGE in direction of arrow out of armrest.

Disconnect associated plug connection and remove rocker switch for side window operation (1).

Scheme 1432

Installation

Retaining hooks (1) of rocker switch for side window operation (2) must not be damaged.

Make sure rocker switch for side window operation (2) is correctly seated in armrest.

Scheme 1433

61 31 116 Replacing rocker switch for side window operation (rear)

Scheme 1434

Lever rocker switch for side window operation (1) with special tool 00 9 317 WEDGE in direction of arrow out of armrest.

Disconnect associated plug connection and remove rocker switch for side window operation (1).

Installation

Retaining hooks (1) of rocker switch for side window operation (2) must not be damaged.

Make sure rocker switch for side window operation (2) is correctly seated in armrest.

61 31 204 Replacing switch combination for seat adjustment

Necessary preliminary tasks

1. Remove outer cover . See «REMOVING AND INSTALLING/REPLACING OUTER COVER ON LEFT OR RIGHT FRONT SEAT BACKREST»(/bmw/m3/e90-2007-2013/remont/seats/#seats-repair-e90__52-13-040-removing-and-installingreplacing) or «REMOVING AND INSTALLING/REPLACING OUTER COVER ON FRONT LEFT OR RIGHT SEAT (NORMAL)»(/bmw/m3/e90-2007-2013/remont/seats/#seats-repair-e90__52-14-040-removing-and-installingreplacing) on front seat

Unlock retaining tabs (3) in direction of arrow and remove switch combination (1) from cover.

Disconnect plug connection (2).

Scheme 1435

Installation

Retaining tabs (3) of cover and guide (4) of switch combination (1) must not be damaged.

Make sure switch combination (1) is correctly seated in retaining tabs (3).

61 31 255 Replacing switch for door mirror

Operation is described in

Replacing ROCKER SWITCH FOR SIDE WINDOW OPERATION

61 31 270 Replacing switch for reversing light

Note. The installation location of the reversing light switch can vary, depending on the transmission model.

Necessary preliminary tasks

1. If necessary, remove rear underbody protection

Version A

Disconnect plug connection (1).

Release switch for reversing light (2).

Tightening torque 61 31 2AZ .

Scheme 1436

Version B

Disconnect plug connection (1).

Release switch for reversing light (2).

Tightening torque 61 31 2AZ .

Scheme 1437

61 33 060 Removing and installing/replacing both fanfare horns (M3)

Necessary preliminary tasks

1. Remove «FRONT LEFT WHEEL ARCH TRIM»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-71-038-removing-and-installingreplacing)

Note. Headlight shown removed for purposes of clarity.

Disconnect plug connection (1).

Unscrew nuts (2).

Remove fanfare horns (3) from holder (4).

Scheme 1438

61 35 679 Initializing rain/light (solar) sensor

Note. Initialization is necessary: after replacing windscreen after replacing rain/light (solar) sensor after replacing optical element on rain/light (solar) sensor after installing a used rain/light (solar) sensor

Note. Connect BMW diagnosis system Initializing rain/light (solar) sensor

61 35... Notes on ESD protection (Electro Static Discharge)

Note. Electrical components which are particularly sensitive to electrostatic discharge (electronic control units, sensors, etc.) are marked with the ESD warning symbol. E -Electro S -Static D -Discharge

Statically charged persons can discharge themselves when they touch electrical components.

Note. Humans can only detect a discharge starting from a level of approx. 3000 V. The danger threshold for electrical components already starts from a level of approx. 100 V.

Scheme 1439

Example

Mechatronic control unit.

Scheme 1440

Scheme 1441

Personal protective equipment

Electrically conducting clothing (high wool content, antistatic shoes required).

These can primarily be identified by the logo on the side.

Scheme 1442

Scheme 1443

84 10 050 Removing and installing (replacing) USB hub

Necessary preliminary tasks

1. Remove «LEFT FRONT SEAT»(/bmw/m3/e90-2007-2013/remont/seats/#seats-repair-e90__52-13-000-removing-and-installing)
2. Remove «FRONT LEFT ENTRANCE COVER STRIP»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-47-000-removing-and-installingreplacing)
3. Fold back carpet for passenger compartment at front left in direction of travel

Remove USB hub protective socket (1) from footwell insert (2).

Unlock catches (3) with a suitable tool and remove USB hub protective socket cover (5).

Installation

Make sure USB hub protective socket cover (5) engages correctly on USB hub protective socket lower section.

Seal (4) must not be damaged; if necessary, replace USB hub protective socket cover (5).

Scheme 1444

Remove USB hub (1) from USB hub protective socket lower section (2).

Installation

Make sure rubber grommet (4) is correctly seated on USB hub protective socket lower section (2).

Scheme 1445

Disconnect plug connection (3).

61 35 015 Removing and installing (replacing) control unit for Car Access System

Note. The comfort access system is a radio-based system and can be interfered with by radio waves from other systems (e.g. mobile phone).

Necessary preliminary tasks

1. Remove «TRIM FOR PEDAL ASSEMBLY»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-45-185-removing-and-installingreplacing)

Disconnect plug connection (2).

Scheme 1446

Release screw (3).

Feed out control unit for Car Access System (4) to left and remove in downward direction.

Installation

Feed guide (1) of control unit for Car Access System (2) correctly into associated mounting.

Scheme 1447

Replacement

1. Carry out vehicle programming and encoding
2. Version with independent heating: Initialize Telestart hand transmitter See «INITIALIZING TELESTART HANDHELD TRANSMITTER (T93) (FROM BUILD DATE 03/2007)»(/bmw/m3/e90-2007-2013/remont/automatic-hvac-system/#heating-and-air-conditioning-repair-e90__64-12-initializing-telestart-handheld-transmitter) or «INITIALIZING TELESTART HAND TRANSMITTER (T90) (UP TO BUILD DATE 03/2007)»(/bmw/m3/e90-2007-2013/remont/automatic-hvac-system/#heating-and-air-conditioning-repair-e90__64-12-initializing-telestart-hand-transmitter) .

61 35 950 Removing and installing (replacing) control unit for comfort access system

Necessary preliminary tasks

1. Remove «TRIM FROM REAR APRON»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-46-050-removing-and-installingreplacing)
2. Remove «RIGHT LUGGAGE COMPARTMENT TRIM PANEL»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-47-161-removing-and-installingreplacing)
3. Partially detach insulating mat

Release screws (1) and pull back device holder (2).

Scheme 1448

Unfasten plug connection (1) and disconnect.

Unlock catch (2) in direction of arrow and remove control unit for comfort access system (3) upwards from device carrier (4).

Scheme 1449

Replacement

Carry out vehicle programming and encoding.

61 35 080 Removing and installing (replacing) control unit for left or right seat adjustment (front seat)

Note. To facilitate installation/removal of control unit, move seat upwards fully.

Unlock metal lug (1) towards front and remove control unit for seat adjustment (2) towards bottom.

Unlock and disconnect all associated plug connections.

Scheme 1450

Installation

Make sure control unit for seat adjustment (1) is correctly seated in mounting (2).

Guides (3) and metal lug (4) must not be damaged.

Scheme 1451

Replacement

Carry out vehicle programming and encoding.

84 21 542 Removing and installing (replacing) hands-free charging electronics (High)

Note. Comply with notes and instructions on HANDLING OPTICAL WAVEGUIDES .

Necessary preliminary tasks

1. Disconnect «BATTERY NEGATIVE»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-20-900-disconnecting-and-connecting) lead
2. Remove «LUGGAGE COMPARTMENT FLOOR TRIM»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-47-101-removing-and-installingreplacing)

E91

Release retaining clips (1) and remove storage pan (2).

Fold panel (3) upwards.

Scheme 1452

Unscrew nuts (1).

Remove holder for telematics control unit/SES (2) in direction of arrow from body.

Scheme 1453

E88/E93

Raise panel for luggage compartment partition (4) slightly and feed out holder for telematics control unit/SES (2) in direction of luggage compartment.

Release wiring harness fastener (3) from holder for telematics control unit/SES (2).

Installation

Make sure guides (5) are correctly seated in associated body holders.

Make sure wiring harness is correctly laid.

Disconnect plug connection (1).

Release all nuts.

Remove hands-free charging electronics (3) from holder for telematics control unit/SES (2).

Scheme 1454

Replacement

1. Carry out vehicle programming and encoding
2. If necessary, log mobile phone on to vehicle

61 35 177 Removing and installing (replacing) rain/light sensor

Necessary preliminary tasks

Version with Autobeam

1. Remove «INTERIOR REAR-VIEW MIRROR»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-16-060-removing-and-installingreplacing)

Detach two-part mirror base cover (1) by pressing from below.

Feed out two-part mirror base cover (1) and remove.

Note. Catches of two-part mirror base cover (1) must not be damaged or missing.

Scheme 1455

Disconnect plug connection (3).

Release locks (1) in direction of arrow and remove rain/light sensor (2) from optical element.

Installation note

Do not damage optical element covered by rain/light sensor (2).

Initialize RAIN/LIGHT SENSOR .

Scheme 1456

61 35 107 Removing and installing or replacing Junction Box electronics

Necessary preliminary tasks

1. Disconnect «BATTERY NEGATIVE LEAD»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-20-900-disconnecting-and-connecting)
2. Remove «FOOTWELL SIDE TRIM PANEL»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-43-075-removing-and-installingreplacing) on A-pillar, right
3. Remove «TRIM FOR INSTRUMENT PANEL»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-45-181-removing-and-installingreplacing) , bottom right

Note. Glovebox removed for purposes of clarity.

Disconnect plug connection (1).

Release screws (2) and remove junction box electronics (3) from holder.

Scheme 1457

Disconnect plug connection (1).

Installation

Make sure junction box electronics is correctly seated on plug connection (2) of holder.

Scheme 1458

Replacement

Carry out vehicle programming and encoding.

Delete transport mode.

Note. DC/DC converter in vehicles with automatic start-stop function.

There are two versions

1. Without additional bracket for diesel engine vehicles
2. With additional bracket for gasoline engine vehicles

Depending on the equipment, one or both versions are installed in the M3

Necessary preliminary work

Remove lower section of microfilter housing (all except M3)

Remove RIGHT UPPER SECTION OF MICROFILTER HOUSING M3

Unlock fasteners (1) from below and slide upwards approx. 10 mm.

Unlock locks (2) in direction of arrow.

Remove cover (3).

Diesel engine vehicles (without additional bracket)

Release lugs in direction of arrow. Remove DC/DC converter (1) by pulling upward. Disconnect plug connection (2).

Gasoline engine vehicles (with additional bracket)

Release lugs in direction of arrow. Remove DC/DC converter (1) by pulling upward. Disconnect plug connection (2).

M3

Release tabs in direction of arrow and remove DC/DC converter with additional bracket (1) upward. Disconnect plug connection (2).

Release tabs in direction of arrow and remove DC/DC converter without additional bracket (3) upward. Disconnect plug connection (4).

61 35 975 Removing and installing/replacing bumper antenna for Comfort Access System

Necessary preliminary tasks

1. Remove «REAR BUMPER TRIM»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-12-156-removing-and-installing)

Disconnect plug connection (2).

Unlock catches (1) and remove bumper antenna for comfort access system (3) in direction of arrow from holder.

Installation

Make sure bumper aerial/antenna for comfort access system (3) is correctly seated in holder.

Scheme 1459

61 35 115 Removing and installing/replacing footwell module

Necessary preliminary tasks

1. Clamp off «BATTERY NEGATIVE LEAD»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-35-notes-on-esd-protection)
2. Remove «FOOTWELL SIDE TRIM PANEL ON A-PILLAR, LEFT»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#general-electrical-system-repair-e90__61-20-900-disconnecting-and-connecting)

Disconnect plug connection (1).

Release nuts (2) and remove footwell module (3).

Scheme 1460

REPLACEMENT

Carry out vehicle programming and encoding.

61 35 953 Removing and installing/replacing interior antenna for comfort access system

Necessary preliminary tasks

1. Remove «TRIM FOR STORAGE TRAY»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-16-212-removing-and-installing)

Disconnect plug connection (1).

Unlock retaining hook (2) and remove interior antenna for comfort access system (3) in direction of arrow.

Scheme 1461

61 35 954 Removing and installing/replacing interior antenna for comfort access system (rear)

Move with special tool 00 9323 SCRAPER from below behind trim (1) and release catches (2).

Release trim (1) towards rear from catches (3).

If necessary, disconnect plug connections and remove trim (1).

Installation

Catches (1 and 3) must not be damaged.

Guides (2) must not be damaged

Disconnect plug connection (1).

Unlock retaining hook (2) and remove luggage compartment antenna for comfort access system (3).

Scheme 1462

61 35 970 Removing and installing/replacing rear luggage compartment antenna for comfort access system

Necessary preliminary tasks

1. Remove «LUGGAGE COMPARTMENT FLOOR TRIM PANEL»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-47-101-removing-and-installingreplacing) .

Disconnect plug connection (1).

Unlock catches (2) and remove luggage compartment antenna for comfort access system (3) in direction of arrow from holder (4).

Scheme 1463

64 11 970 Replacing fogging sensor

Expand two-part mirror base cover (1) by pressing from below and detach.

Feed out two-part mirror base cover (1) and remove.

Disconnect plug connection (1).

Note. If necessary, carefully heat fogging sensor (2) with a hot air blower to approx. 40-60°C.

Scheme 1464

Lift off fogging sensor (2) with special tool 00 9 317 WEDGE and slowly pull off from windshield.

Installation

Bonding surface must be dry and free of dust and grease.

Clean bonding surface with adhesive remover (sourcing reference: BMW Parts Service).

After cleaning, do not touch bonding surface with bare hands.

Pull off protective film completely from fogging sensor (3).

Place mounting template (1) as pictured on rain sensor (2).

Press fogging sensor (3) in direction of arrow with a contact pressure of > or =15 N/cm 2 onto inside of windshield.

Note. Firm thumb pressure attains approx. 30 N/cm 2 .

Remove mounting template (1) carefully from fogging sensor (3).

Scheme 1465

61 35 502 Replacing the trailer module (09/2006 - 03/2009)

Note. From 03/2009 trailer module AHM3+ will be replaced by trailer module AHM4R. Plug connectors and associated pin assignments must be adapted if the old plug connector AHM3(+) is fitted. Plug connector, new AHM4 Plug connector, old AHM3(+)

Scheme 1466

Necessary preliminary tasks

1. Remove trailer module

From build date/version 03/2007 Series E60/61

Installation

Cut out device holder up to marking (1).

Cut out indentation in area (2).

Make sure AHM module is exactly seated and wiring harness is correctly routed.

Scheme 1467

Note. Positions of plugs and associated pin assignments are set out in the diagnosis system.

The repair instruction represents the highest vehicle configuration. Pin assignments of plug connections may be absent if optional equipments are not fitted.

Special tools for disconnecting

Secondary lock

Special tool 61 0 324 RELEASE TOOL

Primary lock

Special tool 61 0 316 RELEASE TOOL

Special tool for crimping

Double flat spring contact

Crimping tool special tool 61 0 202 (crimping tool) with special tool 61 0 230 MATRIX (matrix)

SPECIAL CRIMPING TOOLS DESCRIPTION CHART

Carry out vehicle programming and encoding.

61 00... Vehicle programming and encoding

Note. In order to avoid incorrect programming procedures and error messages, it is essential when working with the Progman/ISTA/P programming system always to use the latest Progman version. Battery voltage must not drop below 13.0 V during programming.

Connect battery charger prior to programming.

Programming sequence via ISTA/P

1. Identify vehicle and read out control unit data
2. Draw up and configure measures plan
3. Prepare programming, export CBS/CKM data
4. Carry out repair measures, replace control units if necessary
5. Identify vehicle again after repair. Update measures plan
6. Carry out programming
7. Assess programming afterwards, import CBS/CKM data
8. Programming successfully completed

Programming sequence via Progman

Select menu item (1).

Select corresponding procedure from selection list.

For example

1. Preparation and subsequent evaluation of vehicle programming
2. Start a Progman session
3. Sequence of BMW/MINI vehicle programming and encoding
4. BMW/MINI Car & Key Memory
5. BMW/MINI initialization
6. BMW/MINI service functions in Progman

Scheme 1468

Open locking clip (1) for the corresponding cable.

Scheme 1469

With special tool 61 1 136 or 61 1 137 (pressing-off tool), press back retaining hooks (2) of appropriate contact and pull out cable with contact.

Place special tool 61 1 153 against relay carrier (1) and carefully pull in direction of arrow until the locking tabs (2) of the relay carrier are raised up.

Pull relay carrier (2) in direction of arrow into the first catch (3).

Press down arrester hook (4) of corresponding contact and pull out the cable with contact.

With special tool 61 1 136 or 61 1 137 (press out) press out dual spring contacts.

Note. DC/DC converter in vehicles with automatic start-stop function. There are two versions: Without additional bracket for diesel engine vehicles With additional bracket for gasoline engine vehicles Depending on the equipment, one or both versions are installed in the M3

Necessary preliminary work

Remove lower section of microfilter housing (all except M3)

Remove RIGHT UPPER SECTION OF MICROFILTER HOUSING M3

Unlock fasteners (1) from below and slide upwards approx. 10 mm.

Unlock locks (2) in direction of arrow.

Remove cover (3).

Diesel engine vehicles (without additional bracket)

Release lugs in direction of arrow. Remove DC/DC converter (1) by pulling upward.

Disconnect plug connection (2).

Gasoline engine vehicles (with additional bracket)

Release lugs in direction of arrow. Remove DC/DC converter (1) by pulling upward.

Disconnect plug connection (2).

M3

Release tabs in direction of arrow and remove DC/DC converter with additional bracket (1) upward. Disconnect plug connection (2).

Release tabs in direction of arrow and remove DC/DC converter without additional bracket (3) upward. Disconnect plug connection (4).

61 61... Adjusting left or right windscreen wiper

Correctly adjusting the contact angle of the wiper arms on the windscreen increases wiping quality. For adjustment, refer to the vehicle-specific repair instruction.

Scheme 1470

A/B = Distance between windscreen wiper blade (2) and trim panel on cowl panel (1)

Note. Measurement is taken at the height of the locators (3) for the windscreen wiper arms

C= Contact angle between wiper blade center plane and windscreen

When adjusting with special tool 61 6 100 MEASURING DEVICE , set the scale value in accordance with the following table.

For RHD vehicles, change the preceding sign of the scale values.

1. LHD cars, scale range 0 to -10
2. RHD cars, scale range 0 to +10