Restraints and Towing - Repair BMW M5 E60/E61

71 60... Replacing gaiter for self-swinging-out trailer tow hitch (from 03/2007)

Necessary preliminary tasks

1. Remove rear «BUMPER TRIM»(ref-297477-S13471979042008090200000) .

Unclip cable holder (1).

Lever out gaiter (2) with special tool 00 9 317 (wedge) and slide in direction of arrow.

Swing out self-swinging-out trailer tow hitch.

Scheme 1

Release screws (1) and remove socket (2).

Tightening torque: 5 Nm

Scheme 2

Pull off gaiter (1) in direction of arrow from ball rod.

Scheme 3

71 60... Replacing complete trailer tow hitch

Necessary preliminary tasks

1. Remove «REAR BUMPER TRIM»(ref-297477-S13471979042008090200000) .

Detach impact absorber (1) on both sides.

Scheme 4

Release screws (1).

Installation

Replace screws (1).

Tightening torque: see 1AZ in 71 60 TRAILER TOW HITCH

Remove trailer tow hitch carrier with a 2nd person helping and disconnect associated plug connections.

Scheme 5

71 60 100 Removing and installing/replacing control unit for trailer tow hitch unlocking

Necessary preliminary tasks

1. Open «LUGGAGE COMPARTMENT FLOOR TRIM PANEL»(ref-297477-S37164142922008090200000) .
2. Remove spare wheel
3. Remove cover for control units

Remove control unit (2) and disconnect plug connection (1).

Scheme 6

Replacement

A control unit of the fully automatic trailer tow hitch with is not initialized indicates this by way of the LED in the button.

Initialization sequence

1. If necessary, connect battery charger
2. Ignition off
3. Rear lid open
4. Press and hold down button for fully automatic trailer tow hitch The ball hitch must in the process be pivoted at least once completely from one end stop to the other. If initialization is successful and the ball hitch is in an end position, the LED on the button is permanently lit green.

72 Safety precautions and general information

Notes on safety

1. «SAFETY REGULATIONS»(/bmw/m5/e60e61-2004-2010/remont/towing-systems/#restraints-and-towing-repair__72-00-safety-regulations-for-handling) for handling airbag modules, airbag components and pyrotechnical seat belt tensioners
2. «NOTES ON SCRAPPING»(/bmw/m5/e60e61-2004-2010/remont/towing-systems/#restraints-and-towing-repair__72-12-notes-on-scrapping-vehicles) vehicles with gas generators
3. «DEACTIVATION/ACTIVATION PYROTECHNICAL COMPONENTS»(/bmw/m5/e60e61-2004-2010/remont/towing-systems/#restraints-and-towing-repair__72-12-deactivation-of-airbags)

Handling electrical and electronic equipment

1. «UNLOCKING/LOCKING AIRBAG PLUG CONNECTIONS»(/bmw/m5/e60e61-2004-2010/remont/towing-systems/#restraints-and-towing-repair__72-12-unlockinglocking-airbag-plug-connections)
2. «REPAIRING AIRBAG LINES»(ref-297480-S07747549312008090200000)
3. «HANDLING OPTICAL FIBERS»(ref-297480-S30861722172008090200000)

Check

1. «CHECK SEAT BELT»(/bmw/m5/e60e61-2004-2010/remont/towing-systems/#restraints-and-towing-repair__72-11-checking-automatic-safety-belt)
2. «CHECKLIST FOR SEAT BELT»(/bmw/m5/e60e61-2004-2010/remont/towing-systems/#restraints-and-towing-repair__72-11-check-list-for-automatic)

Airbag system

1. Functional description and checking, refer to BMW Diagnosis System
2. «DEACTIVATING AIRBAGS»(/bmw/m5/e60e61-2004-2010/remont/towing-systems/#restraints-and-towing-repair__72-12-deactivating-front-passenger-airbags)
3. «PROCEDURE AFTER AIRBAG DEPLOYMENT»(/bmw/m5/e60e61-2004-2010/remont/towing-systems/#restraints-and-towing-repair__72-12-procedure-after-airbag-deployment)

72 00... Safety regulations for handling components with gas generators

It is essential to comply with the regulations as specified in the law relating to the use of explosives when working on airbag units and seat belt tensioners.

Airbags, seat belt tensioners etc. are pyrotechnical objects. Pyrotechnical objects are assigned to different danger classes on the basis of the quantity of propellant that they contain. The assignment can be ascertained from the identification marking on the product

This applies in particular to the following components

1. Airbag modules (driver's/front passenger airbags, side airbags)
2. Buckle/belt tensioner
3. Head airbag (ITS, AHPS)
4. Active knee protection
5. Active head restraint
6. Safety battery terminal (SBK)

1. Regulations The regulations quoted in the following, refer to the German regulations. In all other countries, the relevant legislation and regulations must be observed in each case. Country-specific legal regulations that go beyond this information or court decisions based thereon must be followed in each case or given precedence over these regulations. The following components used by BMW: Pyrotechnical restraint systems are subject to danger class PT1 Gas generators are pyrotechnical objects belonging to danger class T1. Handling, transporting and storing non-fired gas generators are subject to the "Explosive Materials Act" (law relating to the use of explosives dated 13/09/1976). The relevant trade supervisory authority must be notified at least 2 weeks before pyrotechnical objects are handled for the first time. Here the relevant authority must be notified in writing of the person responsible (e.g. dealership owner, holder of general power of attorney or if necessary workshop supervisor). A certificate of qualification, i.e. specific training, is not required for the person responsible.
2. Disassembly and assembly Inspection, testing and installation work may only be carried out by expert trained personnel in BMW Service. Work on components of the airbag system should only ever be carried out with the battery disconnected, the negative terminal post covered and the plug connection of the cable leading to the gas generator disconnected. If only the battery is disconnected, the following prescribed waiting period must be observed without fail: 30 minutes for vehicles up to 9/93; 1 minute for vehicles from 9/93 In the event of breaks in work, a component with a gas generator that has been removed must be secured against access by other persons. Individual components must never be repaired. Instead, always replace them. Do not treat airbag system components with cleaning agents or grease. Components of the airbag system must not be exposed to temperatures in excess of 75°C. Airbag system components, including electronic diagnostic components, which have been dropped from heights in excess of 0.5 m must not be reinstalled in the vehicles. Before installing, subject airbag system components (including electronic diagnostic components) to a visual inspection for damage and replace if necessary. Airbag system components may only be electrically tested while they are installed and only with the BMW diagnostic system / DIS. Danger of injury: The airbag module may only be set down with the airbag itself facing upwards. Otherwise the generator will be thrown upwards if it is fired. Do not point the firing pellet of a gas generator at other persons. Components with gas generators must not be fired while they are removed. They must be disposed of by special disposal companies or returned to BMW in the packaging of the new components. When carrying out straightening and welding work with an electric welder: Disconnect battery Cover negative terminal (post) Avoid all contact with the skin when removing a fired airbag module - wear gloves. Wash with water after contact with the skin.
3. Transport Components with gas generators must be sent off in the packaging of the new components.
4. Storage Observe the regulations of the relevant trade supervisory authority and the applicable national regulations.

72 11... Checking automatic safety belt

General considerations when checking seat belts

The seat belts must be checked after an accident.

For the check, you should start by trying to get information on which seats in the car involved in the accident were occupied. If this is not possible, check all the seat belts in the car and replace them if necessary.

In the event of deformations on the car, you must subject the components of the restraint system affected in this area such as e.g.

1. Seat belt
2. Seatbelt height adjustment
3. Belt buckle tensioner
4. Triggering sensors
5. etc.

to a function check and a visual inspection.

If you are in any doubt as to the unimpaired functional capability of restraint system components, these components must be replaced in the interests of safety!

If a seat belt has to be replaced following an accident (e.g. in the event of a frontal and/or side impact with permanently deformed impact dampers/deformation elements or cross-members), the complete seat belt must be replaced! The complete seat belt comprises

1. Top belt
2. Lower strap
3. Seat belt buckle (buckle tensioner)
4. Seatbelt height adjustment
5. Retaining screws of all components

The following must also be checked and if necessary replaced

1. Seatbelt mountings on the car body
2. Seatbelt mountings on the seat
3. seat runners.
4. Seat structure (frame, etc.)

Alignment tests on the seat and the seat runners are not permitted!

The following explanations and the checklist for the automatic safety belt can provide help.

An unusable seat belt or a seat belt worn in a serious accident should be destroyed immediately after removal to guarantee that it cannot be used again.

Checking automatic reel and seatbelt strap

The automatic reel has two independent activation systems for seat-belt locking.

The first activation system locks the automatic reel when driving quickly around curves, driving in tight curves, on extreme inclinations (vehicle rolls over) and during sharp braking or impact.

To check, the seat backrest must be placed in the upright position and both hands held in a supporting position close to the steering wheel. The brakes are then applied fully while driving on a dry surface and at a road speed equal to twice that of walking speed.

The seat belt must lock.

The second activation system provides additional safety and is controlled by inertia mass.

If the reel locks when the strap is pulled out suddenly, this system is also OK.

Automatic reel does not require servicing and must not be opened.

Precondition for complete, problem-free retraction of straps

1. the straps must not be twisted!
2. the straps must not be damaged!

When placed to one side, the straps of the front seats must retract fully.

With the straps in the rear seat bench, a small remaining loop is acceptable due to increased friction between the strap and the rear seat bench cover if

1. this remaining loop is fully retracted when the strap is reguided.

Belt straps should only be cleaned with a luke-warm soap solution or a commercial laundry detergent.

Belt straps must never be cleaned chemically or dyed.

The automatic reel and strap must be replaced in the event of

1. creases
2. unraveling
3. pinches
4. cracks and tears
5. traces of melting
6. traces of wear on casing of seat belt tongue or on reversing clip.

Checking lower strap (belt buckle tensioner)

To fasten a seat belt, the tongue should insert easily and with a loud click in the lock.

When the "Red button" is pressed, the tongue must be ejected from the lock under spring pressure.

If the lock cover is missing or damaged, the lower strap must be replaced.

Replace the triggered belt buckle tensioner including the complete seat belt with seatbelt height adjustment and retaining screws and check the

1. Seatbelt mountings on the car body
2. Seatbelt mountings on the seat
3. seat runners.
4. Seat structure.

Criteria for a triggered mechanical belt buckle tensioner

1. very low position of seatbelt buckle (comparisons with new part).

Criteria for a triggered pyrotechnical belt buckle tensioner

1. very low position of seatbelt buckle (comparisons with new part).
2. Airbag warning lamp permanently lit: read out airbag system fault memory.

The belt buckle tensioners can be triggered under certain circumstances even when the seat is not occupied. If it is definite that the belt system was not used (seat was not occupied), there is no need to replace the following items after a check

1. upper strap
2. attachment parts (belt height adjustment, screws)
3. seatbelt mountings on the car body
4. Seatbelt mountings on the seat
5. Seat rails

Checking end fitting pretensioner

Replace the triggered end fitting pretensioner including the complete seat belt with seat belt height adjustment, lower strap, and mounting bolts and check the following items

1. Seatbelt mounts on the vehicle body
2. Seatbelt mounts on the seat
3. Seat rails
4. Seat structure

Criteria for a triggered end fitting pretensioner

1. A triggered end fitting pretensioner can be recognized from the wrapped seat belt strap around the shaft.
2. Airbag indicator light permanently lit: read out airbag system fault memory.

72 11... Check list for automatic seat belt

INSPECTION LIST FOR AUTOMATIC SEAT BELT

72 11 021 Removing and installing/replacing left or right seat belt (reel)

Necessary preliminary tasks

1. Remove «PANEL FOR DOOR POST»(ref-297477-S29943737992008090200000) .
2. Remove outer trim on front seat. See «BASIC/ELECTRIC SEAT»(ref-297478-S28351346582008090200000) or «COMFORT SEAT»(ref-297478-S26496816972008090200000) .

Note. Version with anchor fitting tensioner for driver's seat only.

Release screw (1).

Tightening torque: see 5AZ in 72 11 SEAT BELTS .

Scheme 7

Release screws (1).

Tightening torque: see 3AZ in 72 11 SEAT BELTS .

Remove belt guide (2).

Unscrew bolt (3).

Tightening torque: see 3AZ in 72 11 SEAT BELTS .

Remove belt (4).

Scheme 8

Release screw (1).

Tightening torque: see 1AZ in 72 11 SEAT BELTS .

Remove automatic reel (3).

Installation

Coding (2) of automatic reel must be seated in body opening.

Retaining screw (1) locates automatic reel in position.

Scheme 9

72 11 033 Removing and installing/replacing front left or right seat belt (reel)

Necessary preliminary tasks

1. Remove «PANEL FOR DOOR POST»(ref-297477-S29943737992008090200000) .

Switch off ignition!

Manual/semi-electric seat adjustment only

Lever out plug (1).

Release screw (2).

Tightening torque: see 5AZ in 72 11 SEAT BELTS .

Scheme 10

Driver's seat with anchor fitting tensioner only: (from 04/2004)

If necessary, detach felt.

Using screwdriver, press pin (1) into recess and release anchor fitting (2).

Installation

Anchor fitting (2) is coded.

Scheme 11

Release screws (1).

Tightening torque: see 3AZ in 72 11 SEAT BELTS .

Remove belt guide (2).

Unscrew bolt (3).

Tightening torque: see 2AZ in 72 11 SEAT BELTS .

Remove belt (4).

Release screw (1).

Tightening torque: see 1AZ in 72 11 SEAT BELTS .

Remove automatic reel (3).

Installation

Coding (2) of automatic reel must be seated in body opening.

Retaining screw (1) locates automatic reel in position.

72 11 041 Removing and installing/replacing front left or right lower belt fitting (seat belt tensioner)

Necessary preliminary tasks

1. Remove «SEAT»(ref-297478-S12577311832008090200000)

Switch off ignition!

Release screw (1).

Tightening torque: see 6AZ in 72 11 SEAT BELTS .

Disconnect plug connection (2) and plug connection of lead (3).

Remove lower strap (belt tensioner) (4).

Scheme 12

72 11 050 Removing and installing/replacing front belt anchor fitting tensioner (driver seat only)

Switch off ignition!

Necessary preliminary tasks

1. Remove «UPPER RAIL TRIM»(ref-297478-S02182899102008090200000) .

Disconnect cable straps.

Installation

Replace faulty cable straps.

Plug connection must not be under tension.

Unfasten plug connection (1) and disconnect.

Release screw (2).

Tightening torque: see 8AZ in 72 11 SEAT BELTS .

Remove anchor fitting tensioner (3).

Installation

Secure plug connection with felt strip against unlocking.

Scheme 13

If necessary, detach felt.

Using screwdriver, press pin (1) into recess and release anchor fitting (2).

Installation

Anchor fitting (2) is coded.

72 11 102 Removing and installing/replacing all rear seat belts

Necessary preliminary tasks

1. Remove «PANEL FOR REAR WINDOW SHELF»(ref-297477-S03056682032008090200000)
2. Remove «REAR SEAT»(ref-297478-S42485468302008090200000)

Removing left and right inertia reel units

Release screw (1) on left and right inertia reel units (2).

Tightening torque: see 20AZ in 72 11 SEAT BELTS .

Remove left and right inertia reel units (2).

Removing middle inertia reel unit

Unscrew bolt (3).

Tightening torque: see 20AZ in 72 11 SEAT BELTS .

Remove inertia reel unit (4).

Installation

Guide lug of inertia reel unit (4) must be correctly seated in opening in body.

Scheme 14

Installation

Pay attention to coding on inertia reel unit (1) and on body (2).

Scheme 15

Release screws (2) on left and right.

Tightening torque: see 22AZ in 72 11 SEAT BELTS .

Remove left and right seat belts (1).

Installation

Secure fittings of left and right seat belts (1) through guides (2) and stop (3).

Scheme 16

Removing lower strap receptacles

lease screws (1).

Tightening torque: see 23AZ in 72 11 SEAT BELTS .

Remove lower strap receptacles (2).

Remove middle upper strap (3).

Scheme 17

Installation

Ensure correct installation sequence and installation position

Scheme 18

1. Fittings of center lower strap/center upper strap must rest on stop (1).
2. Secure lower strap on left and right through guides (2).

72 11 302 Removing and installing/replacing all seat belts (comfort)

Necessary preliminary tasks

1. Remove «TRIM FOR PARCEL SHELF»(ref-297477-S03056682032008090200000)
2. Remove «REAR SEAT»(ref-297478-S42485468302008090200000)

Switch off ignition!

Removing left and right seat belts

Release screw (1) from automatic reel (2) on left and right.

Tightening torque: see 20AZ in 72 11 SEAT BELTS .

Remove automatic reels (2) on left and right.

Unscrew bolt (3).

Tightening torque: see 20AZ in 72 11 SEAT BELTS .

Remove automatic reel (4).

Installation

Guide lug of automatic reels (2 & 4) must be seated in body opening.

Release screws (2) on left and right.

Tightening torque: see 22AZ in 72 11 SEAT BELTS .

Remove left and right seat belts (1).

Installation

Secure fittings of seat belts (1) on left and right through stop (3) in guide.

Release screws (1).

Tightening torque: see 23AZ in 72 11 SEAT BELTS .

Remove lower strap (2) on left and right.

Remove lower strap (3).

Installation

Holder for lower strap (3) must be fitted below lower strap on right (2).

Scheme 19

52 13 385 Replacing gas cartridge (pyroactivator) for crash-active head restraint on front seat

Switch off ignition!

Necessary preliminary tasks

1. Disconnect «BATTERY NEGATIVE LEAD»(ref-297480-S05650650142008090200000) .
2. Remove «CRASH-ACTIVE HEAD RESTRAINT»(ref-297478-S37165337622008090200000) .

Starting situation

Head restraint is in the crash position after being triggered.

Note. Pyroactivator can only be removed in the triggered state. The complete crash-active head restraint must be replaced if the event of a head restraint fault signal and an untriggered pyroactivator.

Scheme 20

Removing cover

Raise cover (1) and pull towards rear.

Scheme 21

Removing pyrotechnical device

Press together retainer (1) for pyrotechnical device at lugs.

Feed out pyrotechnical device.

Scheme 22

Removing pyroactivator

Pull pyroactivator (2) out of mounting (1) for pyrotechnical device.

Unlock plug connection (3) and disconnect.

Scheme 23

Procedure for installing pyrotechnical device

Bringing head restraint together - version without button (MFS)

Pull spring catches apart and push head restraint together.

Maintain position.

Scheme 24

Bringing head restraint together - version with button (Basic)

Press button (1) and push head restraint together.

Maintain position.

Scheme 25

Locking release plate

Hold pushed-together head restraint in position and push release plate (1) upwards up to stop.

Release plate (1) must audibly snap into place.

Scheme 26

Checking head restraint lock

Check end position of release plate (1).

All four springs must be engaged (snapped into place).

Scheme 27

Replacing pyrotechnical device

Connect plug (1) to new pyroactivator (2) and lock.

Clip pyroactivator (2) into new mounting (3).

Scheme 28

Installing pyrotechnical device

Press together retainer for pyrotechnical device at lugs.

Insert retainer for pyrotechnical device into release plate and tilt in upward direction.

Retainer for pyrotechnical device must audibly snap into place.

Note. Check seating of retaining lugs in retainer.

Scheme 29

Laying wiring harness

Secure wiring harness in carrier section with strain relief.

Scheme 30

Mounting cover

Clip cover onto carrier section.

Cover must audibly snap into place.

Scheme 31

61 00... Repairing airbag cables

Safety regulations

See SAFETY REGULATIONS for handling components of airbag system.

Follow INSTRUCTIONS for disconnecting and connecting battery.

Procedure for cable repair

In event of non-visible damage to wiring harness

Disconnect plug connection on airbag module or on adapter plug. It is absolutely vital to disconnect the contacts in succession as there is a risk of them being mixed up! Cut through one cable after the other at an appropriate position, do not under any circumstances cut through both cables at the same time. Insulate cables remaining in wiring harness with insulating tape. Now disconnect plug connection on airbag control unit. Unpin contacts. Cut through one cable after the other at an appropriate position and insulate with insulating tape, do not under any circumstances cut through both cables at the same time. Pin contacts of repair cable for airbag control unit in control unit plug, assignment of repair cables is relevant. Lay repair cable in car parallel to existing airbag lead. Now pin in contacts for airbag control unit or contacts of adapter plug, assignment of repair cables is relevant. Cut off excess length of repair cable in proximity (visible area) of airbag module or of adapter plug. Twist open cables. With the connectors and shrink-fit hoses in the Electronic Parts Catalogue (EPC), reconnect the cables with the same cable colors. Twist cables again, open length (twist) must not exceed 40 mm. Secure interface (shrink-fit hoses) with insulating tape to prevent cables from twisting open.

For instructions for cutting off, insulating, crimping cables, installing and removing contacts, see

CUTTING OFF AND INSULATING CABLES

REPAIRING A PLUG CONNECTION USING CONNECTORS

INSTALLING AND REMOVING CONTACTS

In event of visible damage

Expose cable at damaged areas. Cut through one cable after the other at an appropriate position and insulate cables no longer required in wiring harness with insulating tape, do not under any circumstances cut through both cables at the same time. Now, depending on the scope of work, unpin contacts either on airbag control unit/airbag module or on adapter plug. Cut off unpinned cables. Insulate cables remaining in wiring harness with insulating tape. Now pin in contacts of repair cable, assignment of repair cables is relevant. Lay repair lead in car parallel to existing airbag lead up to cutting point. Cut off excess length of repair lead. Twist open cables. Connect cables with connectors and shrink-fit hoses in Electronic Parts Catalogue (EPC), assignment of repair cables is relevant. Twist cables again, open length (twist) must not exceed 40 mm. Secure interface (shrink-fit hoses) with insulating tape to prevent cables from twisting open.

72 12... Deactivating front passenger airbags with key switch

The passenger airbag can only be deactivated in accordance with the following instructions if the vehicle is equipped with a suitable key-operated switch!

The key switch can be retrofitted if it is missing and has been ordered as an optional extra.

Key-operated switch

1. Optional extra SA 5DA for MINI
2. Optional extra SA 470 for BMW

E83 up to 09/2004 only

see DEACTIVATION OF AIRBAGS

E83 from 09/2004 only

Deactivation via key-operated switch, see following work steps

R50/R53 up to 04/2004 only

see DEACTIVATION OF AIRBAGS

R50/R53 from 04/2004 only

Deactivation via key-operated switch, see following work steps

The following airbags are deactivated simultaneously with the key-operated switch (1)

1. Passenger airbag
2. Side airbag (passenger side)
3. If necessary, knee airbag in US models (passenger side)

The airbags can only be deactivated/reactivated while the vehicle is stationary and with the door open.

Scheme 32

Deactivation

Scheme 33

1. Turn key-operated switch with ignition key to "OFF" position. Deactivate airbags on passenger side out of operation. Head airbag on passenger side remains active. All airbags on driver side remain active. Activation
2. Turn key-operated switch with ignition key to "ON" position. All the airbags in the vehicle are activated and are triggered in appropriate situations.

Indicator light

When the ignition key is turned in the ignition lock, the function of the airbag system is checked and the warning lamp in the center console lights up for several seconds.

Scheme 34

1. The indicator light is permanently ON when the front passenger airbags are deactivated
2. The indicator light goes out after a few seconds when the front passenger airbags are activated

72 12... Deactivation of airbags

The following airbags can be (de-)activated

1. Passenger airbag
2. Side airbag (front passenger), front
3. Side airbag (front passenger), rear

R50/R53 up to 04/2004 and E83 up to 09/2004 only

For details of deactivation, see following work steps.

R50/R53 from 04/2004 and E83 from 09/2004 only

See DEACTIVATING FRONT PASSENGER AIRBAG WITH KEY SWITCH

Necessary preliminary tasks

1. Read and comply with «SAFETY REGULATIONS»(/bmw/m5/e60e61-2004-2010/remont/towing-systems/#restraints-and-towing-repair__72-safety-precautions-and-general-information)
2. Disconnect «BATTERY»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__12-00-notes-for-disconnecting-and)

Front-passenger airbag

Note. Seat occupancy detector remains connected. Expose plug connection of passenger airbag. Disconnect plug connection. Tie back disconnected cable and secure with cable strap (rattling noises) Stick on warning signs Code airbag control unit (see BMW Diagnostic System) Documentation of customer consent and storage in car's file Entry in car's documents (Germany only) Replacement of passenger belt with belt force limitation by version without belt force limitation

Side airbag, front

Scheme 35

1. Expose plug connection of side airbag
2. Disconnect plug connection of corresponding side airbags
3. Tie back disconnected cables and secure with cable strap (rattling noises)
4. Stick on warning signs (see below)
5. Code airbag control unit (see BMW Diagnostic System)
6. Documentation of customer consent and work in car's file
7. Entry in car's documents (Germany only)

Side airbag, rear

Scheme 36

1. Expose plug connection of side airbag
2. Disconnect plug connection of corresponding side airbags
3. Tie back disconnected cables and secure with cable strap (rattling noises)
4. Stick on warning signs (see below)
5. Code airbag control unit (via CIP)
6. Documentation of customer consent and work in car's file
7. Entry in car's documents (Germany only)

Warning sign, passenger airbag

1. Stick on a warning sign with the text "Passenger airbag out of operation" from the inside to the top outer edge of the windshield on the passenger side.

Note. Remove the warning sign when the passenger airbag is reactivated.

Scheme 37

Warning signs, side airbag

Note. Remove warning signs when reactivating side airbags.

Scheme 38

Passenger Airbag Off light (US version or SA only)

1. Remove «AIRBAG OFF INDICATOR»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-31-069-removing-and-installingreplacing) (POL) or trim
2. Disconnect plug from Airbag Off indicator
3. Tie back plug and secure with cable strap (rattling noises)
4. Install trim
5. Code airbag control unit

Function check airbag warning light (except US version)

The function of the airbag system is checked when the ignition key is turned in the ignition switch.

FUNCTION CHECK CHART

Note. A coding of the airbag control unit must be carried out so that the warning lamp goes out again after deactivation.

72 12... Notes on scrapping vehicles with gas generators (airbag system)

The gas generator is a pyrotechnical component and is for the most part permanently mounted on the following components

1. Airbag module Driver's/passenger airbag Side airbag Head airbag (e.g. AHPS2) Knee airbag
2. Belt tensioner
3. Belt buckle tensioner
4. Safety battery terminal
5. Active head restraint

In accordance with accident prevention regulations and specific national regulations, gas generators must be rendered unusable before they are scrapped. This is necessary because pyrotechnical objects can cause injury if improperly activated (e.g. scrapping with flame cutters).

With vehicles which are scheduled for scrapping, it is always essential prior to draining and further stripping work to ensure that all the gas generators in the vehicle are fired. The fired gas generators can then be scrapped together with the vehicle.

Gas generators that have not fired constitute a hazard (also to the environment)!

Firing failure

If correct firing is not possible, the relevant components must be removed and disposed of by special waste disposal companies!

Comply with SAFETY REGULATIONS for handling airbag system components.

If a firing operation has failed

1. Disconnect the firing device from the battery and
2. Only approach the vehicle after a few minutes have elapsed

The components of an airbag system must always be disposed of. Such components must not be sold on as used parts.

Firing

Firing of the gas generators may only be carried out by expert personnel and under the supervision of a responsible person. Other standard accident prevention regulations (safety goggles, ear defenders etc.) must also be observed.

The gas generators must be fired from the outside in this vehicle which has been earmarked for scrapping. In this process

1. the doors must be closed
2. the rear lid must be open
3. the side windows must be open and
4. the sunroof must be open

To fire the gas generators, use the firing device with the appropriate cables (follow instructions).

Scheme 39

72 12... Procedure after airbag deployment as result of an accident

Check and/or replace following components after airbag triggering

Satellites (control unit + sensor)

1. Components Satellite, A-/B-pillar, left/right Satellite, front door Satellite, rear seat Satellite, driver's/front passenger seat Satellite, vehicle center
2. Procedure Read out fault memory Disconnect battery and observe waiting period Rectify faults Reconnect battery and observe waiting period Clear fault memory Turn off ignition and wait at least 2 minutes (no consumers may be switched on during this period such as e.g. inside lights, radio, etc.) Switch ignition on Clear fault memory and if necessary rectify faults

Cables and connectors

1. Components and procedure Check cables and plugs for damage, replace if necessary.

Seat belt system

1. Components Retractor mechanism Belt buckle tensioner Seatbelt height adjustment
2. Procedure Check components, replace if necessary

Seats

1. Components Seat Airbag module Active head restraint
2. Procedure Check seats (function check of seat mechanism), replace if necessary Check seat screw/bolt connections Replace gas generator, active head restraint system If the severity of the impact has not caused any other damage to the seat, only the triggered gas generator needs to be replaced. External feature: The triggered head restraint is folded forwards and engaged. The repair work can be carried out in the car with the rear panel removed. The entire system can be pushed back into its original position and the new gas generator installed. The gas generator can be replaced up to 5 times. Replace airbag module and seat cover with padding

Driver's airbag

1. Components Airbag module Steering wheel Steering column (if damaged)
2. Procedure Check components, replace if necessary Replace steering wheel

Front passenger airbag

1. Components Airbag module Instrument panel trim Supporting tube (if damaged)
2. Procedure Check components, replace if necessary

Side airbag, front/rear

1. Components Airbag module Door trim panel Door in white Seat
2. Procedure Check components, replace if necessary

Head airbag

1. Components Airbag module Trim, A-pillar Roofliner Trim, B-pillar (if damaged) Trim, C-pillar (if damaged) Connection/mounting (on side frame)
2. Procedure Check components, replace if necessary

Knee airbag

1. Components Panel (driver's side) Lower section of glovebox Active knee protector (driver's and passenger sides)
2. Procedure Check components, replace if necessary

Passive knee protection

1. Components Panel (driver's side) Glovebox incl. knee protector (passenger side)
2. Procedure Check components for damage, replace if necessary Check fastening element

72 12... Unlocking/locking airbag plug connections

Following versions of plug connections on airbag module/gas generator are possible

1. Airbag plug connection on gas generator/airbag module is offset by 90°
2. Airbag plug connection on gas generator/airbag module is straight (3 versions)

Airbag plug connection on gas generator/airbag module offset by 90°

There are two ways of unlocking this airbag plug connection on the gas generator/airbag module

Method 1

Simultaneously pull cover (1) upwards at lugs on left and right (2).

Scheme 40

Method 2

Insert a narrow screwdriver into recess (1) in housing (2).

Carefully pry cover (3) off (4).

Scheme 41

Cover (1) is not positioned higher than housing (2).

The airbag plug connection is unlocked and can now be detached from the gas generator/airbag module.

Scheme 42

Installation

After attaching airbag plug connection to gas generator/airbag module, press cover (1) downwards until it rests flat on housing.

Check that it catches properly.

Scheme 43

Airbag plug connection on gas generator/airbag module is straight (2 versions)

Version 1

Press locking/unlocking plate (1) at edge (4).

Locking/unlocking plate (1) snaps upwards at opposite edge (3) and releases detent lug (2).

Scheme 44

The airbag plug connection is unlocked and can now be detached from the gas generator/airbag module.

Scheme 45

Installation

After attaching airbag plug connection to gas generator/airbag module, check whether detent lug (2) is visible in opening of locking/unlocking plate (1).

Only if the detent lug (2) is visible will the airbag plug connection gas generator/airbag module be correctly engaged.

Scheme 46

Version 2

Press locking/unlocking plate (1) on edge (3) and pull plug (2) out of plug housing (4).

Installation

Only if the detent lug is visible in opening (5) will the gas generator/airbag module plug connection be correctly engaged.

Scheme 47

Version 3

Press lock button (1) and pull out plug (2) up to initial engagement position.

Detach plug (2) from firing pellet.

Installation

Insert plug connection in initial engagement position in gas generator/airbag module and engage in final engagement position.

Scheme 48

Illustration of version 3 with gas generator

1. Initial engagement position
2. Final engagement position

Scheme 49

1. Lock button
2. Gas generator

Version 4 - Crash-active head restraint

Press locking clip at edge and disconnect plug (1).

Installation

Check for correct engagement.

Scheme 50

72 12 000 Removing and installing/replacing airbag module on passenger side

Necessary preliminary tasks

1. Disconnect «BATTERY NEGATIVE LEAD»(ref-297480-S02774300402008090200000)
2. Follow «INSTRUCTIONS»(/bmw/m5/e60e61-2004-2010/remont/towing-systems/#restraints-and-towing-repair__72-12-unlockinglocking-airbag-plug-connections) for unlocking and locking airbag plug connections
3. Remove «GLOVEBOX»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-366-removing-and-installing) with housing

Version (E60/E61) with front drinks holder

1. Remove front «OUTER CUP HOLDER CARRIER»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-removing-and-installingreplacing-front)
2. Release front «INNER CUP HOLDER CARRIER»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-removing-and-installingreplacing-front) Inner carrier can only be removed together with airbag module.

Unfasten plug connection (1) and disconnect. Remove plug connection from holder (by turning).

E63/ E64

Release screws (3) and carefully feed out airbag module (2) towards bottom.

E60

Release screws (3); if necessary, slide front inner cup holder carrier slightly to one side.

Carefully remove airbag module (2), if necessary with front inner cup holder carrier, towards bottom rear.

Scheme 51

Installation

When inserting airbag module (1) in channel (2), make sure channel rests all round airbag module. If necessary, pull channel apart at sides.

Replace screws.

Tightening torque: see 2AZ in 72 12 AIRBAG MODULES .

Scheme 52

72 12 010 Removing and installing/replacing airbag module on left or right front door

Necessary preliminary tasks

1. Disconnect «BATTERY CABLE»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting) Follow «INSTRUCTIONS»(ref-297480-S05650650142008090200000) for disconnecting and connecting battery.
2. Remove «FRONT DOOR TRIM»(ref-297477-S07770139542008090200000) .

Unfasten screws.

Carefully remove airbag module.

Installation

Before installing airbag module, remove all foreign bodies (screws, etc.) from installation recess.

Replace screws.

Tightening torque: see 1AZ in 72 12 AIRBAG MODULES .

Scheme 53

72 12 015 Removing and installing/replacing airbag module on left or right rear door

Necessary preliminary tasks

1. Disconnect «BATTERY CABLE»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting) Follow «INSTRUCTIONS»(ref-297480-S05650650142008090200000) for disconnecting and connecting battery.
2. Remove «REAR DOOR TRIM»(ref-297477-S41186688132008090200000) .

Unfasten screws.

Carefully remove airbag module.

Installation

Before installing airbag module, remove all foreign bodies (screws, etc.) from installation recess.

Replace screws.

Tightening torque: see 1AZ in 72 12 AIRBAG MODULES .

Scheme 54

72 12 045 Removing and installing/replacing left or right AHPS2 head airbag

Necessary preliminary tasks

1. Remove luggage compartment trim on side panel. See «TRUNK TRIM PANEL ON LEFT SIDE PANEL»(ref-297477-S27600701182008090200000) or «TRUNK TRIM PANEL ON RIGHT SIDE PANEL»(ref-297477-S16005522492008090200000) .
2. Disconnect «BATTERY CABLE»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting) . Follow «INSTRUCTIONS»(ref-297480-S05650650142008090200000) for disconnecting and connecting battery.
3. Remove roofliner. See «HEADLINER (WITH SLIDE/TILT SUNROOF)»(ref-297477-S26254391522008090200000) or «HEADLINER (WITHOUT SLIDE/TILT SUNROOF)»(ref-297477-S10193195502008090200000) .

Release all screws (1) of holders.

Tightening torque: see 3AZ in 72 12 AIRBAG MODULES .

Feed all holders (2) out of sheet metal flange.

Scheme 55

Note. The retainers behind the holders can break off. These retainers serve as an installation aid during series production and are not important for repairs.

Release rear screw.

Tightening torque: see 4AZ in 72 12 AIRBAG MODULES .

Remove rear AHPS2.

Scheme 56

Release front screws (1 and 2).

Tightening torques

1. Screw 1: see 4AZ in «72 12 AIRBAG MODULES»(/bmw/m5/e60e61-2004-2010/remont/towing-systems/#restraints-and-towing-tightening-torques)
2. Screw 2: see 6AZ in «72 12 AIRBAG MODULES»(/bmw/m5/e60e61-2004-2010/remont/towing-systems/#restraints-and-towing-tightening-torques)

Carefully feed gas generator out of guides towards rear, unlocking and disconnecting plug (3) in the process.

Remove gas generator completely.

Scheme 57

Security version

Gas generator (1) is mechanically modified, spare part changed.

Scheme 58

Note. View of retaining screw with anchor fitting of AHPS2 head airbag: Anchor fitting, AHPS2 head airbag Lock washer Retaining screw

Installation

Observe the following when replacing grommet

Scheme 59

1. Catches (1) must not be damaged
2. Pay attention to guide lug (2) when feeding into body

72 14... Removing and installing/replacing Top Tether eyelets for child seat

Note. Two or three Top Tether eyelets are installed, depending on the model.

Lever out covers (1) and release screws underneath.

Remove Top Tether eyelets (2).

Tightening torque: see 3AZ in 52 24 REAR SEAT (NORMAL), MANUAL .

Scheme 60

Scheme 61

See also:
• 71 60 TRAILER TOW HITCH
• 72 11 SEAT BELTS
• BATTERY
• AIRBAG OFF INDICATOR
• GLOVEBOX
• OUTER CUP HOLDER CARRIER
• 72 12 AIRBAG MODULES
• BATTERY CABLE
• SAFETY REGULATIONS
• NOTES ON SCRAPPING
• DEACTIVATION/ACTIVATION PYROTECHNICAL COMPONENTS
• UNLOCKING/LOCKING AIRBAG PLUG CONNECTIONS
• CHECK SEAT BELT
• CHECKLIST FOR SEAT BELT
• DEACTIVATING AIRBAGS
• PROCEDURE AFTER AIRBAG DEPLOYMENT
• SAFETY REGULATIONS