General Electrical System - Repair BMW M6 E63/E64

12 00 ... Instructions on starting aid

Do not start the engine with help of starting sprays.

Preparation

Conform with the following when starting engine with starting cable.

1. Ensure that jump lead wires are to appropriate cross-section size.
2. Only use fuse-protected jump leads.
3. Check whether the current supplying battery has 12 V voltage.
4. If engine is started from 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.

Carrying out

Always conform with the procedures to avoid injury to persons or damage to parts.

1. On automatic transmission, select "P" setting, apply handbrake.
2. Move the shift lever of vehicles with manual transmission into neutral and apply the parking brake.
3. Ensure that the jump leads cannot get caught in rotating parts, e.g. fan.
4. First connect positive terminals of both batteries with one jump lead (red).
5. Use positive connection point in engine compartment for vehicles with one battery in trunk.
6. Then attach second jump lead (black) to negative terminal of donor battery and to engine ground or body ground on vehicle to be started.

Danger of explosion!

After engine of vehicle to be started has started up, first disconnect the jump lead on the negative terminal/ground connection. Then remove jump lead from positive terminals.

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

Note. Version with AFS: After reconnecting the vehicle battery, refer to 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY , carry out the following procedure for setting the steering angle: Start engine. Turn steering wheel left to full lock. Turn steering wheel right to full lock. Turn steering wheel to central position. Turn off engine. 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

1. Connect diagnosis system
2. Clear fault memory

61 00 ... Battery

Note. Important notes and instructions for handling batteries in the dealership can be found in: Battery master document Disconnecting battery, refer to 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY . Battery charging, refer to 61 00 ... BATTERY CHARGING . Welding work, refer to WELDING WORK (OVERLOAD PROTECTION OF CONTROL UNITS) . External jump-starting aid, refer to 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 00 ... Battery charging

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 00 ... Notes on handling optical fibers

1. The minimum permitted bending radius is 25 mm
2. Do not subject optical fibers to compressive and tensile load
3. Protect optical fibers against the effects of heat equal to or greater than 85°C (e.g. during welding work, drying work with infrared heater or hot air blower)
4. Optical fibers are permitted to show only one junction point (bridge), replace optical fibers if necessary

Note. The optical fibers are colored differently as follows

1. Green= MOST (Media Oriented Systems Transport) optical fibers
2. Yellow= ISIS (Intelligent Safety and Integration System) optical fibers
3. Orange = repair optical fibers

Follow instructions for processing cables and optical fibers.

61 00 ... Repairing airbag cables

Safety regulations

Safety regulations for handling components of airbag system.

Instructions for disconnecting and connecting battery, refer to 12 00 ... 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 colours. 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, refer to 61 13 ... OPENING PLUG HOUSINGS AND REMOVING CONTACTS OF DIFFERENT PLUG SYSTEMS .

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.

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 .. 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 1

Press lock and open clip in direction of arrow.

Disconnect plug connection.

Scheme 2

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

Scheme 3

Press lock and disconnect plug connection in direction of arrow.

Scheme 4

Press lock and disconnect plug connection in direction of arrow.

Scheme 5

Press lock and disconnect plug connection in direction of arrow.

Scheme 6

Press lock and disconnect plug connection in direction of arrow.

Scheme 7

Press lock and disconnect plug connection in direction of arrow.

Scheme 8

Press lock and disconnect plug connection in direction of arrow.

Scheme 9

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

Note. Do not connect continuous trickle charger to the cigarette lighter.

The cigarette lighter is powered by the rear distribution box via a relay. This relay drops out after terminal 15 OFF. This means that a continuous trickle charger connected to the cigarette lighter is disconnected from the battery.

Charge the battery via the jump-start connection points. Only then can the power supply be registered by the vehicle.

Warning! Danger of destruction in event of mechanical strain

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.

Warning! Danger of destruction to IBS and cables when battery is replaced

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. Recode the Car Access System (CAS) when installing a battery with a different capacity.
4. Delete fault entries in the Digital Motor Electronics (DME) associated with battery replacement.
5. Always proceed in accordance with the repair instructions.
6. A battery can be drained (e.g. with lights or radio switched on) even when the IBS functions perfectly in conjunction with power management.
7. For this reason, only replace the IBS when a corresponding fault is entered in the DME or DDE.

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

Necessary preliminary tasks

1. Remove left luggage compartment wheel arch trim

Release plastic nuts (1).

Remove underlay for floor panel at rear left (2).

Remove underlay for luggage compartment floor panel (3).

Scheme 10

Disconnect battery negative lead (1).

Disconnect plug connection (2) of one-pin IBS cable (3).

Release nut (5) of safety battery terminal (4), tightening torque, refer to 61 21 1AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUES - 645CI .

Detach safety battery terminal (4) towards top, lay to one side and secure.

Scheme 11

Unlock cable lug mounting (1) and fold back.

Unscrew bolt (2).

Unclip cable lug mounting (1) from positive battery cable (3) and remove.

Scheme 12

Unclip positive battery cable (1) from cable guides (2) and remove.

Scheme 13

61 12 013 Replacing Battery Negative Lead

Necessary preliminary tasks

1. Remove luggage compartment floor trim panel, refer to «51 47 101 REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT FLOOR TRIM PANEL»(ref-202134-S12367961982005102700000) .
2. Remove trim on tail panel, refer to «51 46 050 REMOVING AND INSTALLING/REPLACING TOP TRIM ON REAR APRON»(ref-202134-S30002304942005102700000) .
3. Remove right luggage compartment wheel arch trim, refer to «51 47 161 REMOVING AND INSTALLING/REPLACING RIGHT LUGGAGE COMPARTMENT WHEEL ARCH TRIM»(ref-202134-S05006487052005102700000) .

Remove underlay for floor panel (1).

Release nut (2) on battery negative terminal.

Tightening torque, refer to 61 21 1AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUES - 645CI .

Detach battery negative lead (5) with intelligent battery sensor (IBS) in upward direction.

Disconnect plug connection (3).

Disconnect plug connection (4).

Release nut (6) and battery negative cable (5).

Tightening torque, refer to 61 21 2AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUES - 645CI .

Scheme 14

Replacement

Carry out programming/coding, refer to DIAGNOSIS PROGRAMMING/CODING .

Diagnosis Programming/Coding

Using the current TIS CD

1. Document type: Select SI Diagnosis Coding.
2. Index number 11: Select Programming Information to display the table of contents.
3. Select the current IDC for the appropriate vehicle.

61 12 065 Replacing wiring harness for front bumper

Necessary preliminary tasks

Disconnect plug connections (1) on ultrasonic transducer.

Unclip wiring harness (2) from bumper trim.

Scheme 15

Unlock plug (1) in direction of arrow from bumper trim.

Scheme 16

Installation

Make sure wiring harness (2) is correctly laid.

61 12 067 Replacing Wiring Harness For Rear Bumper

Necessary preliminary tasks

1. Partially remove luggage compartment wheel arch trim on left, refer to «51 47 151 REMOVING AND INSTALLING/REPLACING LEFT LUGGAGE COMPARTMENT WHEEL ARCH TRIM»(ref-202134-S33740613502005102700000) .
2. Remove rear bumper trim, refer to «51 12 156 REMOVING AND INSTALLING REAR BUMPER TRIM»(ref-202134-S03823936922005102700000) .

Unlock and disconnect plug connections (1) from ultrasonic converter.

Unlock and disconnect plug connections (2) on number/licence plate lights. Unlock and disconnect plug connections (3) from rear lights.

Scheme 17

Installation

Make sure wiring harness is correctly laid.

61 12 200 Replacing Wiring Harness In Left Or Right Front Door

Necessary preliminary tasks

1. Close front side window completely
2. Remove luggage compartment floor trim panel
3. Disconnect battery negative lead, refer to «61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting) .
4. Remove trim on armrest of front door, refer to «51 41 075 REMOVING AND INSTALLING/REPLACING TRIM ON ARMREST ON LEFT OR RIGHT REAR DOOR»(ref-202134-S28004954852005102700000) .
5. Remove rocker switch for side window operation, refer to «61 31 115 REPLACING ROCKER SWITCH FOR SIDE-WINDOW OPERATION»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-31-115-replacing-rocker-switch) .
6. Remove front door trim panel, refer to «51 41 000 REMOVING AND INSTALLING LEFT OR RIGHT FRONT DOOR TRIM PANEL»(ref-202134-S17236406042005102700000) .
7. Remove front acoustic insulation, refer to «51 48 060 REMOVING AND INSTALLING/REPLACING SOUND INSULATION IN FRONT DOOR, LEFT OR RIGHT»(ref-202134-S10445230062005102700000) .

Unlock plug connection (3) for outside door mirror and disconnect.

Disconnect cable ties (1) and feed out wiring harness for outside door mirror.

Unlock and disconnect plug connection (2) for speaker.

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

Disconnect plug connection (5) on door pressure sensor.

Scheme 18

Installation

Make sure door wiring harness is correctly laid.

Unfasten plug connection (1) and disconnect.

Unclip wiring harness (2) at points (3).

Scheme 19

Installation

Make sure wiring harness is correctly laid.

Unclip door wiring harness (3) at points (1).

Release expansion rivets (2).

Scheme 20

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 21

Note. Examples of unlocking and disconnecting different plug connections.

Press lock and open clip in direction of arrow.

Disconnect plug connection.

Scheme 22

Press lock and open clip in direction of arrow.

Disconnect plug connection.

Scheme 23

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

Scheme 24

Press lock and disconnect plug connection in direction of arrow.

Scheme 25

Press lock and disconnect plug connection in direction of arrow.

Scheme 26

Press lock and disconnect plug connection in direction of arrow.

Scheme 27

Press lock and disconnect plug connection in direction of arrow.

Scheme 28

Press lock and disconnect plug connection in direction of arrow.

Scheme 29

Press lock and disconnect plug connection in direction of arrow.

Scheme 30

For notes on handling optical fibers, refer to 61 00 ... NOTES ON HANDLING OPTICAL FIBERS

For repairing airbag cables, refer to .

61 13 Special tools for wiring harness repairs

Special tools required

Note. For special tools, refer to BODY ELECTRICAL - SPECIAL TOOLS - 645CI (E63) .

1. 61 1 150
2. 61 1 190
3. 61 4 320
4. 61 8 084
5. 61 9 020
6. 61 9 029
7. 61 9 041
8. 61 9 042
9. 61 9 043
10. 61 9 044

Repair ranges I, II, III for vehicle electrical system

1. Order No.: 81 24 9 408 080
2. Order No.: 81 24 9 408 300
3. Order No.: 81 24 9 408 400

Note. Operating instructions for the special tools contained in TIS article, refer to "Tool for wiring harness repair, repair range I, II, III", special tool 61 8 084.

Scheme 31

Repair range IV for vehicle electrical system, special tool 61 9 020

Contents

1. Special tool 61 9 041 (hand pliers)
2. Special tool 61 9 042 (matrix)
3. Special tool 61 9 043 (wire stripper)
4. Special tool 61 9 044 (matrix)

Scheme 32

Special tool 61 9 043 (wire stripper with wire cutter) for cutting and stripping wires.

Handling

Cutting to length and stripping insulating from cables, refer to 61 13 CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES .

Scheme 33

Special tool 61 9 041 (hand pliers) with special tool 61 9 042 (matrix) for crimping connectors and contact tubes for fan connectors up to a wire cross-section of 2.5 mm2 and for pushing on contact tubes for fan connectors.

Handling

Crimping stop parts (contacts), refer to 61 13 CRIMPING ON STOP PARTS .

Fan connector for retrofitting/repairs, refer to 61 13 INSTALLING FAN CONNECTOR FOR RETROFITTING/REPAIRS .

Scheme 34

Special tool 61 9 041 (hand pliers) with special tool 61 9 044 (matrix) for crimping cable guide and strain relief device on antenna elbow plug.

Handling

Antenna elbow plug on radio receiver, refer to 61 13 ... ANTENNA ELBOW PLUG ON RADIO RECEIVER .

Scheme 35

Special tool 61 1 150 (release and pressing-out tool) for

1. releasing round plug housings
2. releasing relay carriers
3. pressing out contacts
4. removing indicator lights

Scheme 36

Handling

Opening plug housings and removing contacts of different plug systems, refer to 61 13 ... OPENING PLUG HOUSINGS AND REMOVING CONTACTS OF DIFFERENT PLUG SYSTEMS .

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

Handling

Crimping stop parts (contacts), refer to 61 13 CRIMPING ON STOP PARTS .

Service Information 1 03 89 (037)

Scheme 37

Special tool 61 4 320 (crimping set with pliers) for

1. Cutting to length and stripping insulation from optical fibers, refer to «61 13 ... CUTTING OFF, STRIPPING INSULATION AND CUTTING OPTICAL FIBRES TO LENGTH»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-13-cutting-off-stripping) .
2. Crimping optical fibers, refer to «61 13 ... CRIMPING OPTICAL FIBRES»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-13-crimping-optical-fibres) .
3. Crimping MPQ contacts, refer to «61 13 ... CRIMPING MICRO POWER QUADLOCK CONTACTS (MPQ)»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-13-crimping-micro-power) .
4. Crimping MQS contacts, refer to «61 13 ... CRIMPING MICRO QUADLOCK SYSTEM CONTACTS (MQS)»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-13-crimping-micro-quadlock) .

Scheme 38

Special tool 61 1 190 pliers for insulation displacement connector for repairing ribbon cables.

Scheme 39

Handling

Repairing ribbon cables, refer to 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.

Scheme 40

Press lock and open clip in direction of arrow.

Disconnect plug connection.

Scheme 41

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

Scheme 42

Press lock and disconnect plug connection in direction of arrow.

Scheme 43

Press lock and disconnect plug connection in direction of arrow.

Scheme 44

Press lock and disconnect plug connection in direction of arrow.

Scheme 45

Press lock and disconnect plug connection in direction of arrow.

Scheme 46

Press lock and disconnect plug connection in direction of arrow.

Scheme 47

Press lock and disconnect plug connection in direction of arrow.

Scheme 48

61 13 ... Base of tab connector housings

Unlock hook (1) with special tool 61 1 360 and slide plug housing downwards out of base.

Scheme 49

61 13 ... Antenna elbow plug on radio receiver

Cut off faulty antenna angle plug directly after strain relief.

Carefully and with precision, strip insulation from antenna cable as illustrated (lengths given in mm).

Brush shield (copper braid) towards rear.

Scheme 50

Create a loop on inner conductor.

Scheme 51

Tin-plate center connection on antenna angle plug and stripped inner conductor.

Solder inner conductor on center connection with a small soldering iron (max. 50 watts) and matching soldering tip (1).

Gently push insulation forward to soldering point and pay attention to correct position of loop.

Note. The loop must not under any circumstances come into contact with the metal parts of the antenna plug.

Scheme 52

Special tool 61 9 041 (hand pliers) in conjunction with special tool 61 9 044 (matrix) is used to crimp antenna angle plug.

Special tools for wiring harness repairs

Scheme 53

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 54

Place antenna angle plug with cable guide and strain relief in matrix (1).

Scheme 55

Compress special tool 61 9 041 as far as it will go.

Special tool 61 9 041 unlocks automatically.

Remove antenna angle plug with antenna cable from special tool 61 9 044.

Scheme 56

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

Special tools required

Note. For special tools, refer to BODY ELECTRICAL - SPECIAL TOOLS - 645CI (E63) .

1. 61 4 320

To crimp MPQ contacts, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 325 (2) from crimping set 61 4 320.

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

Scheme 57

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 58

Note. Follow procedure for cutting and stripping insulation from cables, refer to 61 13 CUTTING TO LENGTH 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, refer to 61 13 CRIMPING ON STOP PARTS .

Scheme 59

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

Special tools required

Note. For special tools, refer to BODY ELECTRICAL - SPECIAL TOOLS - 645CI (E63) .

1. 61 4 320

To crimp MQS contacts, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 324 (2) from crimping set 61 4 320.

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

Scheme 60

Open pliers (1).

Fold up contact carrier (2).

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

Fold back contact carrier (2).

Scheme 61

Note. Follow procedure for cutting and stripping insulation from cables, refer to 61 13 CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES .

Close pliers (1) one notch.

Insert stripped cable (2).

Close pliers (1) fully.

Scheme 62

Open pliers (1).

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

Note. Check contact for correct crimping, refer to 61 13 CRIMPING ON STOP PARTS .

Scheme 63

61 13 ... Crimping annular contacts

CrimpacII crimping pliers from repair kit 1 are used to crimp annular contacts.

Scheme 64

Open crimping pliers (1).

Note. Place contact (2) in designated nest (observe wire cross-section) with particular care. Make sure it is exactly positioned.

Insert annular contact (2) in crimping pliers (1).

Close crimping pliers (1) gently and keep closed.

Scheme 65

Note. Follow procedure for cutting and stripping insulation from cables, refer to 61 13 CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES .

Feed stripped cable (1) into annular contact (2) completely.

Close crimping pliers (3) fully.

Open crimping pliers (3) and remove cable (2).

Note. Check contact for correct crimping, refer to 61 13 CRIMPING ON STOP PARTS .

Scheme 66

61 13 ... Crimping optical fibres

Special tools required

Note. For special tools, refer to BODY ELECTRICAL - SPECIAL TOOLS - 645CI (E63) .

1. 61 4 320

To crimp optical fibres, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 323 (2) from crimping set 61 4 320.

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

Scheme 67

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

Scheme 68

Open pliers (2).

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

Scheme 69

Note. Follow procedure for cutting and stripping insulation from optical fibres, refer to 61 13 ... CUTTING OFF, STRIPPING INSULATION AND CUTTING OPTICAL FIBRES TO LENGTH .

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 70

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 71

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

Special tools required

Note. For special tools, refer to BODY ELECTRICAL - SPECIAL TOOLS - 645CI (E63) .

1. 61 4 320

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 61 4 320.

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

Scheme 72

Cutting optical fibre

Open pliers (1).

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

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

Scheme 73

Stripping insulation from optical fibre

Open pliers (1).

Open lever (2) in direction of arrow.

Scheme 74

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 75

Cutting optical fibre to length

Pull pin (1) in direction of arrow.

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

Scheme 76

Remove blade (1) and replace.

Scheme 77

Installation

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

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 78

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

Abbreviations and what they mean

ABBREVIATIONS MEANING

Ultrasonic-welded connectors

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

The contacts of these connectors cannot be replaced. Replace plug completely.

Scheme 79

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

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

Special tools required

Note. For special tools, refer to BODY ELECTRICAL - SPECIAL TOOLS - 645CI (E63) .

1. 61 1 200

Socket housing

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

Scheme 80

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

Scheme 81

Insert special tool 61 1 200 into socket housing (1) and pull out lead with LCC contact (2) in direction of arrow.

Scheme 82

Pin housing

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

Scheme 83

Insert special tool 61 1 200 into pin housing (1) and pull out lead with LCC contact (2) in direction of arrow.

Scheme 84

61 13 ... Relay carrier

Place special tool 61 1 153 on relay carrier (1) and carefully pull in direction of arrow until retaining lugs (2) on relay carrier are raised.

Scheme 85

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

Scheme 86

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

Press out double flat spring contact with special tool 61 1 136 or 61 1 137 (ejector).

Scheme 87

61 13 ... Repairing ribbon cables

Special tools required

Note. For special tools, refer to BODY ELECTRICAL - SPECIAL TOOLS - 645CI (E63) .

1. 61 1 190

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

Scheme 88

Place connector housing (1) in pliers (2) 61 1 190.

Close pliers (2).

Scheme 89

61 13 ... Retaining bracket

Pull relevant fuse out of fuse block (1).

Note. Mark positions when removing fuses.

Pull locking slide (2) out of fuse block (1) as far as it will go.

Scheme 90

With special tool 61 1 136 or 61 1 137 (ejector), press back arrester hook (3) of appropriate contact and pull out cable.

Scheme 91

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 92

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 93

Removing MQS contacts from contact carrier

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

Scheme 94

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 95

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 socket housing where removal of the contacts is identical.

Scheme 96

Hold down arrester hook in secondary lock (1) again. Pull wire with socket contact (2) out of contact carrier (3).

Scheme 97

Removing MPQ contacts from contact carrier

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

Raise lock (2) on radio plug.

Pull contact carrier (3) out of radio plug.

Scheme 98

Press lock (1) in direction of arrow.

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

Scheme 99

Press special tool 61 1 135 on inside of contact into contact carrier (2).

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

Scheme 100

61 13 040 Replacing distribution box (passenger compartment)

Necessary preliminary tasks

1. Remove luggage compartment floor trim panel, refer to «51 47 101 REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT FLOOR TRIM PANEL»(ref-202134-S12367961982005102700000) .
2. Disconnect battery negative lead, refer to «61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting) .
3. Remove trim for instrument panel, bottom left, refer to «51 45 181 REMOVING AND INSTALLING/REPLACING BOTTOM RIGHT TRIM FOR INSTRUMENT PANEL»(ref-202134-S18784146952005102700000) .
4. Remove right glovebox with housing, refer to «51 16 366 REMOVING AND INSTALLING RIGHT GLOVEBOX WITH HOUSING (WITHOUT ACTIVE KNEE PROTECTION)»(ref-202134-S00497280102005102700000) or «51 16 367 REMOVING AND INSTALLING RIGHT GLOVEBOX WITH HOUSING (WITH ACTIVE KNEE PROTECTION)»(ref-202134-S01604084862005102700000) .

Release screws (1) and remove distribution box (2).

Scheme 101

Unlock and disconnect all plug connections (1).

Unlock relay base (3) and disconnect.

Fold up covers (2) from battery positive cable.

Scheme 102

Release nut underneath.

Tightening torque, refer to 61 21 2AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUES - 645CI .

Remove battery positive lead from fuse box.

Installation

Make sure battery positive lead is correctly seated on fuse box.

Replacement

Remove fuses.

61 13 042 Replacing Distribution Box (Luggage Compartment)

Necessary preliminary tasks

1. Remove luggage compartment floor trim panel, refer to «51 47 101 REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT FLOOR TRIM PANEL»(ref-202134-S12367961982005102700000) .
2. Remove control unit cover
3. Disconnect battery negative lead, refer to «61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting) .

Unlock plug connections (1) and disconnect.

Scheme 103

Detach plug connection (1) in direction of arrow and disconnect.

Unlock plug housing (2) and disconnect.

Fold up covers (4).

Unscrew nuts (3).

Tightening torque, refer to 61 21 2AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUES - 645CI .

Pull distribution box upwards out of control unit receptacle.

Scheme 104

Replacement

Remove fuses and relays.

61 13 Cutting To Length And Stripping Insulation From Cables

Special tool 61 9 043 (cable stripper with wire cutter) for cutting and stripping insulation from cables.

Scheme 105

Refer to repair instructions

Special tools for wiring harness repairs, refer to 61 13 SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

Cutting to length

Slide upper handle of cable stripper (6) in direction of arrow until cutting tool (7) becomes visible. Open stripper in final position and hold in this position.

Scheme 106

Hold wire (8) between cutters and squeeze tool handles as far as they will go.

Scheme 107

Stripping insulation

Guide wire (1) until behind knife. Wire length (2) behind knife blade represents the length from which insulation will be stripped.

Scheme 108

Stripped length

WIRE STRIPPED LENGTH

Squeeze tool handles until wire is held tight by jaws (3).

Scheme 109

Continue to squeeze tool handles. This strips insulation from wire (4).

Scheme 110

Open cable stripper and remove stripped wire (5).

Scheme 111

Crimping Butt Connectors And Contact Sleeves For Fan Connectors Up To 2.5 MM2

The special tool 61 9 041 (crimping tool) in conjunction with 61 9 042 (matrix) are used for crimping stop parts (contacts), refer to 61 13 CRIMPING ON STOP PARTS .

Scheme 112

Refer to repair instructions

Special tools for wiring harness repairs, refer to 61 13 SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

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 113

Note. Designation on nests (3) of special tool 61 9 042 indicate which contacts can be used in which crimping nests.

The following wire cross-section sizes and their corresponding stops can be used

Wire cross-section size

1. 0.35 ... 0.5 mm 2
2. 0.75 ... 1.0 mm 2
3. 1.5 mm 3
4. 2.5 mm 2

Scheme 114

Example for choosing a nest

Scheme 115

For further operating instructions, refer to operating instructions for repair range IV for vehicle electrical system 61 9 020.

Insert contact section of contact sleeves (4) for comb connector or crimp connector (5) in predetermined nest.

Scheme 116

Preload contact by squeezing matrix in crimping tool. Grip contact (6) firmly only, do not crimp.

Scheme 117

Note. Follow procedure for cutting and stripping insulation from cable, refer to 61 13 Cutting To Length 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.

Scheme 118

Compress crimping tool as far as it will go.

Crimping tool unlocks automatically.

Take contact out of crimping tool.

Crimping Contact Sleeves For Fan Connectors 4 MM2 And Ignition Cable Contacts

The special tool 12 1 081 (crimping tool) in conjunction with 12 1 083 (matrix) are used to attach the ignition cable contacts and to crimp the contact sleeves 4 mm 2 for fan connectors.

Scheme 119

Refer to repair instructions

61 13 SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

Releasing special tool 12 1 081

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

Scheme 120

OR

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

Insert contact sleeve 4 mm 2 in nest with lock (1) as far as it will go.

Scheme 121

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

Scheme 122

Note. Follow procedure for cutting and stripping insulation from cables, refer to 61 13 CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES .

Insert stripped end of wire (1) in the contact. Ensure insulation and stripped wire end are correctly laid in contact.

Scheme 123

Compress crimping tool as far as it will go.

Crimping tool unlocks automatically.

Take contact out of crimping tool.

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 124

Correct crimping

Visible conductor end (10).

Visible insulation end (11).

Scheme 125

Incorrect crimping

Conductor end (10) inserted too far.

Insulation end (11) in wire crimp.

Scheme 126

If necessary, repeat crimping with a new contact.

Incorrect crimping

Conductor end (10) not visible.

Insulation end (11) not visible.

Scheme 127

If necessary, repeat crimping with a new contact.

For further handling instructions, refer to operating instructions for repair range IV for vehicle electrical system 61 9 020.

61 13 Installing fan connector for retrofitting/repairs

Note. The repair range IV for vehicle electrical system 61 9 020 contains the required special tools and individual parts for retrofitting and repair work with the aid of fan connectors.

Scheme 128

Refer to repair instructions

61 13 SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

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

Scheme 129

Alternatively

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

Scheme 130

Cut through wire loop (1) in wiring harness at determined point (2) with special tool 61 9 043.

Scheme 131

Strip insulation from both wire ends.

Refer to repair instructions

61 13 CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES .

Crimp contact sleeves on both wire ends.

Scheme 132

Refer to repair instructions

61 13 CRIMPING ON STOP PARTS

Crimp connecting cable for retrofitting likewise with contact sleeve.

Scheme 133

Take fan connectors from repair range IV for vehicle electrical system 61 9 020 and cut required number of cores to length.

Scheme 134

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

Scheme 135

Refer to repair instructions

61 13 SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

Unlock special tool 61 9 041

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

Scheme 136

OR

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

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

Scheme 137

Attach wire with contact sleeve to fan connector.

Scheme 138

Press crimping tool together and slide contact sleeve firmly home.

Scheme 139

Push on further contact sleeves for potential branching.

Scheme 140

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 (approx. 250°C) (2).

Scheme 141

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.

Installation in dry area (interior, luggage compartment)

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

Scheme 142

12 00 ... Instructions for disconnecting and connecting battery

Observe safety instructions for handling vehicle battery, refer to 61 00 ... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY .

Before disconnecting battery

Switch off ignition.

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 lead from car battery and second battery if fitted, refer to «61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting) . 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 fitting terminal for battery negative lead: Tightening torque, refer to 61 21 1 AZ in , refer to 61 21 1AZ in «GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUES - 645CI»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-tightening-torques) .

After connecting battery

Vehicles With A Two-Battery System

Starter and equipment batteries

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

Two AGM batteries are used as a storage battery.

Receiving/giving starting assistance via jump start terminal

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 equipment batteries via jump start terminal

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 equipment battery is also included in the charging operation. The secondary control unit automatically detects a charging operation at a charging voltage at the starter battery of greater than or equal to ace;13.5 V. The isolating relay is closed and thus the equipment 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 isolating relay is opened immediately and again only the starter battery is charged.

Note. When the engine hood is open, the isolating 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 isolating 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

Increased closed-circuit current consumption can be compensated with the aid of the battery trickle charger (special tool 61 2 410, for special tool, refer to BODY ELECTRICAL - SPECIAL TOOLS - 645CI (E63) ) via the jump start terminal.

Do not start the engine with help of starting sprays.

Preparation

Conform with the following when starting engine with starting cable.

1. Ensure that jump lead wires are to appropriate cross-section size.
2. Only use fuse-protected jump leads.
3. Check whether the current supplying battery has 12 V voltage.
4. If engine is started from 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.

Carrying out

Always conform with the procedures to avoid injury to persons or damage to parts.

1. On automatic transmission, select "P" setting, apply handbrake.
2. Move the shift lever of vehicles with manual transmission into neutral and apply the parking brake.
3. Ensure that the jump leads cannot get caught in rotating parts, e.g. fan.
4. First connect positive terminals of both batteries with one jump lead (red).
5. Use positive connection point in engine compartment for vehicles with one battery in trunk.
6. Then attach second jump lead (black) to negative terminal of donor battery and to engine ground or body ground on vehicle to be started.

Danger of explosion!

After engine of vehicle to be started has started up, first disconnect the jump lead on the negative terminal/ground connection. Then remove jump lead from positive terminals.

Note. Version with AFS: After reconnecting the vehicle battery, refer to 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY , carry out the following procedure for setting the steering angle: Start engine. Turn steering wheel left to full lock. Turn steering wheel right to full lock. Turn steering wheel to central position. Turn off engine. 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

1. Connect diagnosis system
2. Clear fault memory

For Battery, refer to 61 00 ... BATTERY .

For battery charging, refer to 61 00 ... BATTERY CHARGING .

For safety instructions for handling vehicle battery, refer to 61 00 ... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY .

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

Safety instructions for handling vehicle battery, refer to 61 00 ... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY .

Test step 1 - before charging the battery

BATTERY REFERENCE (BEFORE CHARGING)

Test step 2 - after charging the battery

BATTERY REFERENCE (AFTER CHARGING)

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 ... Battery open-circuit current test

Note. Observe safety instructions for handling vehicle battery, refer to 61 00 ... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY . Observe Service Information Adapter for open-circuit current measurement.

Scheme 143

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

61 20 900 Disconnecting and connecting battery negative lead

Necessary preliminary tasks

1. Remove luggage compartment floor trim panel with fitted mat, refer to «51 47 101 REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT FLOOR TRIM PANEL»(ref-202134-S12367961982005102700000) .

Version with intelligent battery sensor (IBS)

Slacken nut (1).

Tightening torque, refer to 61 21 1AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUES - 645CI .

Detach battery negative lead (3) with IBS (2) in upward direction, lay to one side and secure.

Scheme 144

Version without intelligent battery sensor (IBS)

Disconnect battery negative lead (1).

Tightening torque, refer to 61 21 1AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUES - 645CI .

Scheme 145

For disconnecting and connecting battery negative lead, refer to 61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD .

61 21 010 Removing and installing battery

Necessary preliminary tasks

1. Remove luggage compartment floor trim panel with fitted mat, refer to «51 47 101 REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT FLOOR TRIM PANEL»(ref-202134-S12367961982005102700000) .

Disconnect battery negative lead (1), refer to 61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD .

Disconnect plug connection (2) of one-pin IBS cable (3).

Release nut (5) of safety battery terminal (4), tightening torque, refer to 61 21 1AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUES - 645CI .

Detach safety battery terminal (4) towards top, lay to one side and secure.

Scheme 146

Release both threaded pins (1) and remove both holders (2).

Detach vent (3) in direction of arrow.

Fold both clips (4) open.

Pull back battery (5) towards rear right out of associated mounts.

Lift out battery (5).

Installation

Make sure battery (5) is correctly seated in associated mounts.

Scheme 147

61 30 010 Removing and installing/replacing actuating unit for left or right front seat

This operation is described in

"Removing and installing/replacing outer cover on front seat (sport/electric)", refer to 52 16 040 REMOVING AND INSTALLING/REPLACING OUTER COVER ON FRONT LEFT OR RIGHT SEAT (SPORTS/ELECTRIC) .

Scheme 148

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

Necessary preliminary tasks

1. Remove top section of steering column casing, refer to «32 31 004 REMOVING AND INSTALLING / REPLACING UPPER SECTION OF STEERING COLUMN TRIM»(ref-202129-S07371413242005102700000) .
2. If necessary, remove deformation element for steering column trim.

Note. Comply with notes and instructions on handling optical wave guides, refer to 61 00 ... NOTES ON HANDLING OPTICAL FIBERS .

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).

Scheme 149

Replacement

1. Remove turn indicator/headlight dipping switch, refer to «61 31 016 REMOVING AND INSTALLING/REPLACING TURN INDICATOR/HEADLIGHT DIPPING SWITCH»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-31-016-removing-and-installingreplacing) .
2. Remove windshield wiper switch, refer to «61 31 040 REMOVING AND INSTALLING/REPLACING SWITCH FOR WINDSHIELD WIPERS»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-31-040-removing-and-installingreplacing) .
3. If necessary, remove cruise control switch, refer to «61 31 018 REMOVING AND INSTALLING/REPLACING CRUISE CONTROL SWITCH»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-31-018-removing-and-installingreplacing) .

Replacement

1. Carry out programming/coding, refer to «DIAGNOSIS PROGRAMMING/CODING»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__diagnosis-programmingcoding) .
2. Vehicles without active front steering: Carry out adjustment of steering angle sensor.
3. Vehicles with active front steering: Carry out active front steering start-up/adjustment, refer to «32 10 005 ADJUSTMENT FOR ACTIVE FRONT STEERING»(ref-202129-S07194855802006022700000) .

61 31 006 Removing and installing/replacing fixture for steering column stalk (from 09/2005)

Comply with notes and instructions on handling optical fibres .

Necessary preliminary tasks

1. Remove steering wheel. See «32 33 001 REMOVING AND INSTALLING / REPLACING STEERING WHEEL»(/bmw/m6/e63e64-2005-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-33-001-removing-and-installing)
2. Remove front section of steering column trim. See «32 31 010 REMOVING AND INSTALLING/REPLACING FRONT SECTION OF STEERING COLUMN COVER»(/bmw/m6/e63e64-2005-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-31-010-removing-and-installingreplacing)
3. Remove lower section of steering column trim. See «32 31 020 REMOVING AND INSTALLING / REPLACING LOWER SECTION OF STEERING COLUMN TRIM»(/bmw/m6/e63e64-2005-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-31-020-removing-and-installing)
4. Remove top section of steering column casing. See «32 31 004 REMOVING AND INSTALLING / REPLACING UPPER SECTION OF STEERING COLUMN TRIM»(/bmw/m6/e63e64-2005-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-31-004-removing-and-installing)
5. If necessary, remove deformation element for steering column trim.

Disconnect plug connections from rear on fixture for steering column stalk (2). Release screws (1). Remove fixture for steering column switch (2) in direction of arrow.

Scheme 150

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.

Replacement

1. Remove «turn indicator/headlight dipping switch»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-31-016-removing-and-installingreplacing) .
2. Remove «windshield wiper switch»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-31-040-removing-and-installingreplacing) .
3. If necessary, remove «cruise control switch»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-31-018-removing-and-installingreplacing) .
4. Remove «volute spring cassette»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-31-011-removing-and-installingreplacing) .
5. Carry out vehicle programming/coding.
6. Carry out «steering angle sensor adjustment»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-31-996-carry-out-steering) .

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

61 31 011 Removing and installing/replacing volute spring cassette

Necessary preliminary tasks

1. Remove fixture for steering column stalk

Unlock catches (1) and remove volute spring cassette (2) in direction of arrow from fixture for steering column switch (3).

Scheme 151

Installation

Seat volute spring cassette exactly on plug connections (1), guide (2) and mounts (3).

Scheme 152

61 31 011 Removing and installing/replacing volute spring cassette (from 09/2005)

Necessary preliminary tasks

1. Disconnect «battery negative lead»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair) .
2. Remove airbag unit.
3. Remove steering wheel. «32 33 001 REMOVING AND INSTALLING / REPLACING STEERING WHEEL»(/bmw/m6/e63e64-2005-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-33-001-removing-and-installing)
4. Remove front section of steering column trim. «32 31 010 REMOVING AND INSTALLING/REPLACING FRONT SECTION OF STEERING COLUMN COVER»(/bmw/m6/e63e64-2005-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-31-010-removing-and-installingreplacing)
5. Remove lower section of steering column trim. «32 31 020 REMOVING AND INSTALLING / REPLACING LOWER SECTION OF STEERING COLUMN TRIM»(/bmw/m6/e63e64-2005-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-31-020-removing-and-installing)
6. Remove «cruise control switch»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-31-018-removing-and-installingreplacing) .
7. Remove «windshield wiper switch»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-31-040-removing-and-installingreplacing) .

Release screws (1).

Scheme 153

Unlock catches (1) and remove volute spring cassette (2) in direction of arrow from fixture for steering column switch (3).

Scheme 154

Installation: For purposes of clarity, fixture for steering column stalk (2) is shown removed. Marking (3) must line up with marking (4).

Scheme 155

Installation: Drive pin (1) of volute spring (2) must line up correctly with opening (3) in inner ring of stalk.

Scheme 156

61 31 016 Removing and installing/replacing turn indicator/headlight dipping switch

Necessary preliminary tasks

1. Remove front section of steering column trim, refer to «32 31 010 REMOVING AND INSTALLING/REPLACING FRONT SECTION OF STEERING COLUMN TRIM»(ref-202129-S39474496772005102700000) .

Release screws (1) and remove turn indicator/headlight dipping switch (2) towards rear.

Scheme 157

61 31 018 Removing and installing/replacing cruise control switch

Necessary preliminary tasks

1. Remove front section of steering column trim, refer to «32 31 010 REMOVING AND INSTALLING/REPLACING FRONT SECTION OF STEERING COLUMN TRIM»(ref-202129-S39474496772005102700000) .

Release screws (1) and remove cruise control switch (2) towards rear.

Scheme 158

61 31 020 Removing and installing/replacing ignition starter switch

Necessary preliminary tasks

1. Move ignition lock to key position 0 (stop)
2. Remove lower section of steering column trim, refer to «32 31 020 REMOVING AND INSTALLING / REPLACING LOWER SECTION OF STEERING COLUMN TRIM»(ref-202129-S09193362272005102700000) .

Scheme 159

Installation

Remove screw in bore (2).

Release screws (1), tightening torque, refer to 61 31 1AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUES - 645CI .

Installation

Secure screws (1) with sealing paint.

Remove ignition starter switch (2).

Scheme 160

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

Special tools required

Note. For special tools, refer to BODY ELECTRICAL - SPECIAL TOOLS - 645CI (E63) .

1. 00 9 340

Attach special tool 00 9 340 as illustrated.

Unclip Start/Stop switch (1) with associated ribbon cable.

Scheme 161

Remove Start/Stop switch (1).

61 31 035 Removing and installing/replacing switch for steering column adjustment

Necessary preliminary tasks

1. Remove top section of steering column casing, refer to «32 31 004 REMOVING AND INSTALLING / REPLACING UPPER SECTION OF STEERING COLUMN TRIM»(ref-202129-S07371413242005102700000) .

Disconnect associated plug connections of steering column adjustment switch (1).

Unclip steering column adjustment switch (1) in direction of arrow.

Remove steering column adjustment switch (1) towards front from fixture for steering column stalk (2).

Scheme 162

61 31 037 Removing and installing/replacing lighting control unit

Necessary preliminary tasks

1. Remove left fresh-air grill, refer to «64 22 137 REMOVING AND INSTALLING/REPLACING LEFT FRESH-AIR GRILL»(/bmw/m6/e63e64-2005-2010/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-22-137-removing-and-installingreplacing) .

Replacement

Release screws (1).

Remove lighting control unit (2) from left fresh-air grill (3).

Scheme 163

61 31 038 Removing and installing (replacing) switch for passenger airbag deactivation

Necessary preliminary tasks

1. Disconnect «battery negative lead»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair)
2. Unclip left side cover on instrument panel.

Unlock catches (1) and feed out switch for passenger airbag deactivation (2) to front of cover. Installation: Make sure switch for passenger airbag deactivation (2) is correctly seated in cover.

Scheme 164

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 165

61 31 040 Removing and installing/replacing switch for windshield wipers

Necessary preliminary tasks

1. Remove front section of steering column trim, refer to «32 31 010 REMOVING AND INSTALLING/REPLACING FRONT SECTION OF STEERING COLUMN TRIM»(ref-202129-S39474496772005102700000) .

Release screws (1) and remove windshield wiper switch (2) towards rear.

Scheme 166

61 31 052 Removing and installing/replacing center console switch cluster

Necessary preliminary tasks

1. Remove trim for storage tray, refer to «51 16 212 REMOVING AND INSTALLING TRIM FOR CENTER CONSOLE»(ref-202134-S12282838622005102700000) .

Release screws (1).

Unclip center console switch cluster (2) in direction of arrow from trim for storage tray (3) and remove.

Installation

Make sure center console switch cluster (2) engages correctly in trim for storage tray (3).

Scheme 167

Replacement

Carry out programming/coding, refer to DIAGNOSIS PROGRAMMING/CODING .

61 31 055 Removing and installing/replacing switch for SMG transmission (M5/M6)

Necessary preliminary tasks

1. Remove finisher for preselector lever

Unclip switch for SMG transmission (1) from trim for preselector lever (2). Remove switch for SMG transmission (1) in direction of arrow. Installation: Catch on trim for preselector lever (2) must not be damaged.

Scheme 168

61 31 062 Removing and installing/replacing button for steering wheel heating

This operation is described in: 61 31 035 REMOVING AND INSTALLING/REPLACING SWITCH FOR STEERING COLUMN ADJUSTMENT

61 31 069 Removing and installing/replacing indicator for front passenger airbag deactivation

Necessary preliminary tasks

1. E60, E63: Remove front roofliner trim, refer to «51 44 ... REMOVING AND INSTALLING FRONT ROOFLINER TRIM»(ref-202134-S18045772662005102700000) .
2. E64: Remove front roofliner trim insert

Press locks (1) and unclip indicator for front passenger airbag deactivation (2) in direction of arrow from front roofliner trim (3).

Scheme 169

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

Special tools required

Note. For special tools, refer to BODY ELECTRICAL - SPECIAL TOOLS - 645CI (E63) .

1. 64 1 020

Lever out switch for hazard warning system/central locking (1) with special tool 64 1 020 and pull back.

Disconnect associated plug connection and remove switch for hazard warning system/central locking (1).

Scheme 170

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

Note. To unclip switch for unlocking rear lid (4), partially detach mucket (1). Grip from outside behind footwell side trim panel on A-pillar on left (2).

Press retaining lugs (3) together and feed switch for unlocking rear lid (4) out of footwell side trim panel on A-pillar on left (2).

Disconnect associated plug connection and remove switch for unlocking rear lid (4).

Scheme 171

61 31 103 Removing and installing/replacing left or right shift paddle for SMG transmission

Necessary preliminary tasks

1. Remove «decorative trim for multifunction steering wheel switch»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-31-220-removing-and-installingreplacing) .

Disconnect plug connection (1). Release screws (2). Remove shift paddle for SMG transmission (3) from steering wheel (4).

Installation: Make sure wiring harness is routed exactly. Make sure shift paddle for SMG transmission (3) is correctly seated on steering wheel (4).

Scheme 172

61 31 104 Removing and installing/replacing shifters for SMG transmission (both)

Necessary preliminary tasks

1. Remove steering wheel retaining plate (sports steering wheel), refer to «61 31 220 REMOVING AND INSTALLING/REPLACING MULTIFUNCTION STEERING WHEEL SWITCH (SPORTS STEERING WHEEL)»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-31-220-removing-and-installingreplacing) .

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

Disconnect plug connections (1).

Loosen screws (2).

Remove both shifters for SMG transmission (3) in direction of arrow from sports steering wheel (4).

Installation

Make sure electrical leads are correctly routed.

Scheme 173

61 31 108 Removing and installing/replacing power switch (M5/M6)

Necessary preliminary tasks

1. Remove finisher for preselector lever.

Release screws (1). Remove power switch (2) from trim for preselector lever (3).

Scheme 174

61 31 109 Removing and installing/replacing Dynamic Stability Control switch (M5/M6)

Necessary preliminary tasks

1. Remove finisher for preselector lever.

Release screws (1). Remove switch for Dynamic Stability Control (2) from trim for preselector lever (3).

Scheme 175

61 31 115 Replacing rocker switch for side-window operation

Special tools required

Note. For special tools, refer to BODY ELECTRICAL - SPECIAL TOOLS - 645CI (E63) .

1. 00 9 341

Carefully lever out rocker switch for side window operation (1) with special tool 00 9 341 at specified points (2).

Remove rocker switch for side window operation (1) from door trim panel (3) slightly.

Scheme 176

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

Installation

Retaining clips (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.

Scheme 177

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

Unclip retaining lugs (1) of cover (3) from telephone mounting (2). Fold cover (3) towards front. Installation: Retaining lugs (1) and telephone mounting (2) must not be damaged. Make sure cover (3) is correctly seated on telephone mounting (2).

Scheme 178

Press USB/audio interface connecting socket (1) from rear out of center console base (2). Disconnect plug connections (3) and remove USB/audio interface connecting socket (1).

Installation: Retaining clips (4) and center console base (2) must not be damaged. Make sure USB/audio interface connecting socket (1) is correctly seated on center console base (2).

Scheme 179

61 31 176 Removing and installing/replacing emergency call button

Necessary preliminary tasks

1. Remove front roofliner trim, refer to «51 44 ... REMOVING AND INSTALLING FRONT ROOFLINER TRIM»(ref-202134-S18045772662005102700000) .

Press catches (1) and unclip emergency call button (2) downwards from front roofliner trim (3).

Scheme 180

61 31 177 Removing and installing/replacing switch for slide/tilt sunroof

Necessary preliminary tasks

1. Remove front roofliner trim, refer to «51 44 ... REMOVING AND INSTALLING FRONT ROOFLINER TRIM»(ref-202134-S18045772662005102700000) .

Press catches (1) and unclip switch for slide/tilt sunroof (2) in direction of arrow from front roofliner trim (3).

Scheme 181

Installation

1. Initialize slide/tilt sunroof, refer to «54 0 ... NOTES ON PANORAMA GLASS ROOF (INITIALIZATION/NORMALIZATION/LEARNING OF CHARACTERISTIC CURVE)»(ref-202136-S34713912212005102700000) .

61 31 192 Replacing knob for controller

Detach knob for controller (1) in direction of arrow.

Scheme 182

Installation

Fit knob for controller (1) so that guides (2) are seated in mountings (3).

Press knob for controller (1) in middle until it engages.

Scheme 183

61 31 193 Removing and installing/replacing button unit (for on-board monitor)

Special tools required

Note. For special tools, refer to BODY ELECTRICAL - SPECIAL TOOLS - 645CI (E63) .

1. 00 9 341

Partially fit special tool 00 9 341 as illustrated.

Unclip button unit (1) and lever out in direction of arrow.

Unlock and disconnect associated plug connection, remove button unit (1).

Scheme 184

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

Necessary preliminary tasks

1. Remove knob for controller, refer to «61 31 192 REPLACING KNOB FOR CONTROLLER»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-31-192-replacing-knob-for) .
2. Remove center console, refer to «51 16 200 REMOVING AND INSTALLING STORAGE COMPARTMENT»(ref-202134-S20101411712005102700000) .

Release screws (1).

Remove controller (2) in direction of arrow from storage compartment (3).

Scheme 185

Replacement

Carry out programming/coding, refer to DIAGNOSIS PROGRAMMING/CODING .

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 186

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

Necessary preliminary tasks: Remove storage compartment. See 51 16 200 REMOVING AND INSTALLING STORAGE COMPARTMENT .

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 187

Replacement: Carry out vehicle programming/encoding.

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

This operation is described in: 52 16 040 REMOVING AND INSTALLING/REPLACING OUTER COVER ON FRONT LEFT OR RIGHT SEAT (SPORTS/ELECTRIC)

61 31 214 Removing and installing/replacing switch for Electronic Damper Control (M5/M6)

Necessary preliminary tasks

1. Remove finisher for preselector lever

Release screws (1). Remove switch for Electronic Damper Control (2) from trim for preselector lever (3).

Scheme 188

61 31 220 Removing and installing/replacing multifunction steering wheel switch (sports steering wheel)

Necessary preliminary tasks

1. Remove airbag unit

Note. Illustration shows steering wheel removed.

Release screws (1).

Release complete steering wheel retaining plate (4) with decorative trim (3) in direction of arrow from fixtures (2).

Disconnect associated plug connections and remove complete steering wheel retaining plate (4) with decorative trim (3).

Scheme 189

Installation

Make sure electrical leads are correctly routed.

Note. Illustrations depict removal of the left multifunction steering wheel switch. The right multifunction steering wheel switch is removed in the same way.

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

Installation

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

Scheme 190

61 31 220 Removing and installing/replacing multifunction steering wheel switches (sport steering wheel, from 09/2005)

Necessary preliminary tasks

1. Remove airbag unit

Release screws (1).

Disconnect associated plug connections and remove switches (2) complete with decorative strip (3). Installation: Make sure electrical leads are correctly routed.

Scheme 191

Release screws (2) and remove left multifunction steering wheel switches (3) from decorative strip (1). Installation: Guide pins (4) must not be damaged and must be correctly inserted. Make sure there is a uniform gap between both multifunction steering wheel switches (3) and decorative strip (1).

Scheme 192

61 31 231 Removing and installing/replacing steering wheel electronics control unit

Necessary preliminary tasks

1. Remove airbag unit

E60, E61: Version with standard steering wheel, illustrations show steering wheel removed

Release screws (1).

Remove steering wheel retaining plate (2) upwards out of multifunction steering wheel (3).

Scheme 193

E60, E61: Version with sports steering wheel; E63, E64, illustrations show steering wheel removed

Release screws (1).

Release complete steering wheel retaining plate (4) with decorative trim (3) in direction of arrow from fixtures (2).

Disconnect associated plug connections and remove complete steering wheel retaining plate (4) with decorative trim (3).

Scheme 194

Installation

Make sure electrical leads are correctly routed.

All

Pull steering wheel electronics control unit (1) in direction of arrow out of steering wheel (2).

Scheme 195

Unlock plug connections (1) and disconnect.

Remove steering wheel electronics control unit (2).

Installation

Guide pins (3) of steering wheel electronics control unit (2) must be exactly seated in associated mountings.

Make sure electrical leads (4) are correctly routed.

Scheme 196

61 31 233 Removing and installing/replacing Lane Departure Warning motor electronics (sport steering wheel)

Necessary preliminary tasks

1. Remove «decorative bar from steering wheel»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-31-220-removing-and-installingreplacing) .

Release screws (1) and remove retaining plate (2). Tightening torque, see 32 33 2AZ in 32 33 STEERING WHEEL .

Scheme 197

Disconnect plug connection (1). Release screw (2). Release screws (3) and remove motor electronics (4) complete with electrical wires. Installation: Replace screws (2 and 3). (2) Tightening torque, see 32 33 3AZ in 32 33 STEERING WHEEL , (3) Tightening torque, see 32 33 4AZ in 32 33 STEERING WHEEL . Ensure correct cable routing.

Scheme 198

61 31 241 Removing and installing/replacing engine hood contact switch

Unfasten plug connection (1) and disconnect.

Pull engine hood contact switch (2) in direction of arrow and feed out of microfilter air duct (3).

Scheme 199

61 31 255 Replacing switch for outside mirror

This operation is described in: 61 31 115 REPLACING ROCKER SWITCH FOR SIDE-WINDOW OPERATION .

61 31 270 Removing and installing/replacing switch for reversing light (DME)

Necessary preliminary tasks

1. If necessary, remove rear underbody protection, refer to «51 47 491 REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION»(ref-202134-S15478211762005102700000) .

Unfasten plug connection (1) and disconnect.

Release switch for reversing light (2).

Scheme 200

61 31 287 Removing and installing/replacing driving dynamics switch

Special tools required

Note. For special tools, refer to BODY ELECTRICAL - SPECIAL TOOLS - 645CI (E63) .

1. 64 1 020

Necessary preliminary tasks

1. Remove finisher for preselector lever, refer to «51 16 210 REMOVING AND INSTALLING/REPLACING TRIM FOR PRESELECTOR LEVER (GEARSHIFT LEVER)»(ref-202134-S34135567812005102700000) .

Note. The illustrations show the removal of the driving dynamics switch in versions with automatic transmissions.

Release screws (1).

If necessary, lever out actuation trim (4) with special tool 64 1 020 and remove.

Remove driving dynamics switch (2) in direction of arrow from finisher for preselector lever (3).

Scheme 201

61 31 299 Removing and installing/replacing clutch switch module

Necessary preliminary tasks

1. Remove trim panel for pedal assembly, refer to «51 45 185 REMOVING AND INSTALLING/REPLACING TRIM FOR PEDAL ASSEMBLY»(ref-202134-S35575834462005102700000) .

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 202

Installation

Clutch switch module is protected against incorrect installation.

Clutch switch module must snap audibly into place.

Scheme 203

61 31 310 Replacing brake light switch

Necessary preliminary tasks

1. Remove trim panel for pedal assembly, refer to «51 45 185 REMOVING AND INSTALLING/REPLACING TRIM FOR PEDAL ASSEMBLY»(ref-202134-S35575834462005102700000) .

Unfasten plug connection (1) and disconnect.

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

Installation

Scheme 204

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.

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 205

61 31 330 Removing switch for glovebox light

Special tools required

Note. For special tools, refer to BODY ELECTRICAL - SPECIAL TOOLS - 645CI (E63) .

1. 64 1 020

Lever switch for glovebox light (1) with special tool 64 1 020 as pictured out of glovebox housing (2).

Unlock and disconnect associated plug connection, remove switch for glovebox light (1).

Scheme 206

61 31 382 Replacing level switch for coolant

Release screws (1).

Unlock plug connection for coolant level switch (4) and disconnect.

Pull coolant expansion tank (2) in direction of arrow out of grommet (3) underneath.

Installation

Make sure coolant expansion tank (2) is correctly seated in grommet (3).

If necessary, replace grommet (3).

Scheme 207

Note. For purposes of clarity, illustration shows coolant expansion tank (2) removed.

Turn coolant level switch (1) in direction of arrow, pull upwards out of coolant expansion tank (2) and remove.

Scheme 208

61 31 470 Removing and installing/replacing relay/module

Necessary preliminary tasks

1. Remove luggage compartment floor trim panel, refer to «51 47 101 REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT FLOOR TRIM PANEL»(ref-202134-S12367961982005102700000) .
2. Disconnect battery negative lead, refer to «61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting) .
3. Remove trim for instrument panel, bottom left, refer to «51 45 181 REMOVING AND INSTALLING/REPLACING BOTTOM RIGHT TRIM FOR INSTRUMENT PANEL»(ref-202134-S18784146952005102700000) .
4. Remove right glovebox with housing, refer to «51 16 366 REMOVING AND INSTALLING RIGHT GLOVEBOX WITH HOUSING (WITHOUT ACTIVE KNEE PROTECTION)»(ref-202134-S00497280102005102700000) or «51 16 367 REMOVING AND INSTALLING RIGHT GLOVEBOX WITH HOUSING (WITH ACTIVE KNEE PROTECTION)»(ref-202134-S01604084862005102700000) .

Detach relay (1).

Scheme 209

61 31 492 Replacing level switch for windscreen washer system

Release screws (1).

Detach cover (2) from front underride protection (3) and feed out in direction of arrow.

Remove cover (2).

Scheme 210

E60, E61 with M aerodynamic kit only

Catch any escaping washer fluid if necessary.

Unfasten plug connection (1) and disconnect.

Turn level switch for windscreen washer system (2) in direction of arrow, pull down out of fluid reservoir (3) and remove.

Scheme 211

All others

Catch any escaping washer fluid if necessary.

Unfasten plug connection (1) and disconnect.

Turn level switch for windscreen washer system (2) in direction of arrow, pull down out of fluid reservoir (3) and remove.

Scheme 212

Installation

Fill fluid tank for windscreen washer system.

61 31 996 Carry out steering angle sensor adjustment

Note. Steering angle sensor adjustment must be carried out: after adjustment work on the front axle/steering after all mechanical work on the steering system after the following components have been replaced/coded: Steering column switch cluster DSC control unit ARS control unit

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

61 33 060 Removing and installing/replacing both fanfare horns

Necessary preliminary tasks

1. Remove front right wheel arch trim, refer to «51 71 040 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH COVER»(ref-202134-S23586682412005102700000) .

Unlock plug connections (1) and disconnect.

Release nut (2) and remove low-pitch fanfare horn (3).

Release nut (4) and remove high-pitch fanfare horn (5) with retaining plate.

Scheme 213

32 43 010 Removing and installing / replacing control unit for active front steering

After installation

1. Replacement only: Carry out coding, refer to «DIAGNOSIS PROGRAMMING/CODING»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__diagnosis-programmingcoding) .
2. Replacement/coding only: Carry out adjustment for active front steering, refer to «32 10 005 ADJUSTMENT FOR ACTIVE FRONT STEERING»(ref-202129-S07194855802006022700000) .

Necessary preliminary tasks

1. Remove right entrance strip, refer to «51 47 000 REMOVING AND INSTALLING/REPLACING FRONT (INSIDE) LEFT OR RIGHT ENTRANCE COVER STRIP»(ref-202134-S02681609562005102700000) .
2. Remove right front seat, refer to «52 14 000 REMOVING AND INSTALLING LEFT OR RIGHT FRONT SEAT (NORMAL/ELECTRIC)»(/bmw/m6/e63e64-2005-2010/remont/seats/#seats-repair-instructions-e63__52-14-000-removing-and-installing) or «52 16 000 REMOVING AND INSTALLING FRONT SEAT (SPORTS/ELECTRIC), LEFT OR RIGHT»(/bmw/m6/e63e64-2005-2010/remont/seats/#seats-repair-instructions-e63__52-16-000-removing-and-installing) .
3. Disconnect battery negative lead, refer to «61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting) .
4. If necessary, remove front right floor mat
5. Remove side trim in front right footwell, refer to «51 43 075 REMOVING AND INSTALLING/REPLACING SIDE TRIM PANEL, FOOTWELL, ON A-PILLAR, RIGHT»(ref-202134-S28506220642005102700000) .
6. Fold back front right floor trim
7. Remove kickplate in footwell in front of and next to control unit; if necessary, cut along specified lines with knife and secure later with adhesive tape

Release screws (1).

Tightening torque, refer to 32 43 1AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUES - 645CI .

Lay grounding cable to one side.

Installation

Secure grounding cable as illustrated to retaining plate.

Scheme 214

Raise active front steering control unit and turn over.

Unlock connector and remove.

Remove active front steering control unit.

Scheme 215

Scheme 216

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

Special tools required

Note. For special tools, refer to BODY ELECTRICAL - SPECIAL TOOLS - 645CI (E63) .

1. 12 7 060

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 by touching 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 217

Scheme 218

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

Necessary preliminary tasks

1. Remove trim panel for pedal assembly, refer to «51 45 185 REMOVING AND INSTALLING/REPLACING TRIM FOR PEDAL ASSEMBLY»(ref-202134-S35575834462005102700000) .

Unfasten plug connection (2) and disconnect.

The ribbon cable leads to the ignition starter switch, refer to 61 31 020 REMOVING AND INSTALLING/REPLACING IGNITION STARTER SWITCH .

Release screw (4) and remove control unit for Car Access System (3) in direction of arrow.

Scheme 219

Installation

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

Scheme 220

Replacement

Carry out programming/coding, refer to DIAGNOSIS PROGRAMMING/CODING .

Version with independent heating

Initialize all independent heating remote controls, refer to 64 12 ... INITIALIZING INDEPENDENT HEATING REMOTE CONTROL .

61 35 030 Removing and installing (replacing) power module

Necessary preliminary tasks

1. Remove luggage compartment floor trim, refer to «51 47 101 REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT FLOOR TRIM PANEL»(ref-202134-S12367961982005102700000) .

Unclip electric lead (1) at point (2).

Pull power module (3) slightly out of mounting for control units (4).

Unfasten plug connection (5) and disconnect.

Remove power module (3).

Scheme 221

Replacement

Carry out programming/coding, refer to DIAGNOSIS PROGRAMMING/CODING .

61 35 125 Removing and installing/replacing body module

Necessary preliminary tasks

1. Disconnect battery negative lead, refer to «61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting) .
2. Remove trim for instrument panel, bottom left, refer to «51 45 181 REMOVING AND INSTALLING/REPLACING BOTTOM RIGHT TRIM FOR INSTRUMENT PANEL»(ref-202134-S18784146952005102700000) .
3. Detach airbag control unit with gateway module

Unlock plug connections (1) and disconnect.

Unlock catches (3) in direction of arrow and remove body module (2) from equipment carrier (4).

Scheme 222

Replacement

Carry out programming/coding, refer to DIAGNOSIS PROGRAMMING/CODING .

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

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

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

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

Scheme 223

Disconnect plug connection (3).

Press locks (1) in direction of arrow and remove rain/light sensor (2) towards bottom.

Installation

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

If necessary, initialize rain/light sensor, refer to 61 35 679 INITIALIZING RAIN/LIGHT SENSOR .

Scheme 224

Replacement

Carry out programming/coding, refer to DIAGNOSIS PROGRAMMING/CODING .

61 35 220 Removing and installing (replacing) control unit for left or right front door

Necessary preliminary tasks

1. Remove front door trim, refer to «51 41 000 REMOVING AND INSTALLING LEFT OR RIGHT FRONT DOOR TRIM PANEL»(ref-202134-S17236406042005102700000) .

Unlock plug connections (1) and disconnect.

Release screws (2).

If necessary, unclip electric leads at point (3).

Remove control unit in front door (4).

Scheme 225

Replacement

Carry out programming/coding, refer to DIAGNOSIS PROGRAMMING/CODING .

61 35 285 Removing and installing (replacing) light module

Necessary preliminary tasks

1. Remove trim panel for pedal assembly, refer to «51 45 185 REMOVING AND INSTALLING/REPLACING TRIM FOR PEDAL ASSEMBLY»(ref-202134-S35575834462005102700000) .

Unfasten plug connection (4) and disconnect.

Unlock catch (1) and feed out/remove light module (2) in direction of arrow.

Installation

Make sure light module (2) is correctly seated in mounting (3) and catch (1).

Scheme 226

Replacement

Carry out programming/coding, refer to DIAGNOSIS PROGRAMMING/CODING .

61 35 679 Initializing rain/light sensor

Note. Initialization is necessary

1. After replacing windshield
2. When installing a used rain/light sensor

Note. Connect BMW diagnosis system Initialize rain/light sensor.

61 35 714 Removing and installing/replacing electronic control unit for slide/tilt sunroof (panoramic glass sunroof)

Necessary preliminary tasks

1. Remove trim for instrument panel at bottom right, refer to «51 45 181 REMOVING AND INSTALLING/REPLACING BOTTOM RIGHT TRIM FOR INSTRUMENT PANEL»(ref-202134-S18784146952005102700000) .

Open lock (1) and pull back control unit for slide/tilt sunroof (2).

Unlock and disconnect plug connections (3) and remove control unit for slide/tilt sunroof (2).

Scheme 227

Installation

1. Initialize slide/tilt sunroof, refer to «54 0 ... NOTES ON PANORAMA GLASS ROOF (INITIALIZATION/NORMALIZATION/LEARNING OF CHARACTERISTIC CURVE)»(ref-202136-S34713912212005102700000) .

Replacement

Carry out programming/coding, refer to DIAGNOSIS PROGRAMMING/CODING .

61 35 795 Removing and installing (replacing) control unit for adaptive headlight

Necessary preliminary tasks

1. Remove trim for instrument panel, bottom left, refer to «51 45 181 REMOVING AND INSTALLING/REPLACING BOTTOM RIGHT TRIM FOR INSTRUMENT PANEL»(ref-202134-S18784146952005102700000) .

Unlock catch (1) in direction of arrow.

Pull control unit for adaptive headlight (2) out of equipment carrier (3) slightly.

Unfasten plug connection (4) and disconnect.

Remove control unit for adaptive headlight (2).

Scheme 228

Replacement

Carry out programming/coding, refer to DIAGNOSIS PROGRAMMING/CODING .

61 35 900 Removing and installing/replacing ring antenna of electronic immobilizer

Special tools required

Note. For special tools, refer to BODY ELECTRICAL - SPECIAL TOOLS - 645CI (E63) .

1. 61 3 300

Necessary preliminary tasks

1. Remove top section of steering column casing, refer to «32 31 004 REMOVING AND INSTALLING / REPLACING UPPER SECTION OF STEERING COLUMN TRIM»(ref-202129-S07371413242005102700000) .

Disconnect plug connection (1).

Position special tool 61 3 300 as illustrated with flattened side (A) to ring antenna of electronic immobilizer (2).

Lever out ring antenna of electronic immobilizer (2) in direction of arrow and remove.

Scheme 229

61 35 950 Removing And Installing (Replacing) Control Unit For Comfort 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 luggage compartment floor trim panel, refer to «51 47 101 REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT FLOOR TRIM PANEL»(ref-202134-S12367961982005102700000) .
2. Disconnect battery negative lead, refer to «61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting) .
3. Remove trim for instrument panel, bottom left, refer to «51 45 181 REMOVING AND INSTALLING/REPLACING BOTTOM RIGHT TRIM FOR INSTRUMENT PANEL»(ref-202134-S18784146952005102700000) .

Unfasten plug connection (1) and disconnect.

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

Scheme 230

Installation

Make sure control unit (3) is correctly seated in device carrier (4).

Replacement

Carry out programming/coding, refer to DIAGNOSIS PROGRAMMING/CODING .

61 35 953 Removing And Installing/Replacing Interior Antenna For Comfort Access System (Front)

Necessary preliminary tasks

1. Remove switch for hazard warning system/central locking, refer to «61 31 079 REMOVING AND INSTALLING/REPLACING SWITCH FOR HAZARD WARNING SYSTEM/CENTRAL LOCKING»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-31-079-removing-and-installingreplacing) .
2. Remove center fresh air grill, refer to «64 22 165 REMOVING AND INSTALLING/REPLACING CENTER FRESH-AIR GRILL»(/bmw/m6/e63e64-2005-2010/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-22-165-removing-and-installingreplacing) .
3. Remove middle trim for instrument panel, refer to «51 45 310 REMOVING AND INSTALLING (REPLACING) CENTER TRIM FOR INSTRUMENT PANEL»(ref-202134-S33337117492005102700000) .
4. Remove finisher for preselector lever, refer to «51 16 210 REMOVING AND INSTALLING/REPLACING TRIM FOR PRESELECTOR LEVER (GEARSHIFT LEVER)»(ref-202134-S34135567812005102700000) .
5. Remove driving dynamics switch, refer to «61 31 287 REMOVING AND INSTALLING/REPLACING DRIVING DYNAMICS SWITCH»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-31-287-removing-and-installingreplacing) .
6. Remove trim for storage tray, refer to «51 16 212 REMOVING AND INSTALLING TRIM FOR CENTER CONSOLE»(ref-202134-S12282838622005102700000) .
7. Remove rear seat, refer to «52 24 005 REMOVING AND INSTALLING OR REPLACING REAR SEAT»(/bmw/m6/e63e64-2005-2010/remont/seats/#seats-repair-instructions-e63__52-24-005-removing-and-installing) .
8. Remove rear cup holder, refer to «51 16 204 REMOVING AND INSTALLING/REPLACING REAR CUP HOLDER»(ref-202134-S10033845712005102700000) .
9. Remove storage compartment, refer to «51 16 200 REMOVING AND INSTALLING STORAGE COMPARTMENT»(ref-202134-S20101411712005102700000) .

Version with telephone

1. Disconnect plug for eject box, refer to «84 11 610 REMOVING AND INSTALLING/REPLACING EJECT BOX (CORDLESS KEYPAD HANDSET)»(ref-202143-S09848676302005102700000) .

Release screws (1).

Disconnect plug connection (2).

Remove interior antenna for comfort access system (3).

Scheme 231

61 35 954 Removing And Installing/Replacing Interior Antenna For Comfort Access System (Rear)

Necessary preliminary tasks

1. Remove switch for hazard warning system/central locking, refer to «61 31 079 REMOVING AND INSTALLING/REPLACING SWITCH FOR HAZARD WARNING SYSTEM/CENTRAL LOCKING»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-31-079-removing-and-installingreplacing) .
2. Remove center fresh air grill, refer to «64 22 165 REMOVING AND INSTALLING/REPLACING CENTER FRESH-AIR GRILL»(/bmw/m6/e63e64-2005-2010/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-22-165-removing-and-installingreplacing) .
3. Remove middle trim for instrument panel, refer to «51 45 310 REMOVING AND INSTALLING (REPLACING) CENTER TRIM FOR INSTRUMENT PANEL»(ref-202134-S33337117492005102700000) .
4. Remove finisher for preselector lever, refer to «51 16 210 REMOVING AND INSTALLING/REPLACING TRIM FOR PRESELECTOR LEVER (GEARSHIFT LEVER)»(ref-202134-S34135567812005102700000) .
5. Remove driving dynamics switch, refer to «61 31 287 REMOVING AND INSTALLING/REPLACING DRIVING DYNAMICS SWITCH»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-31-287-removing-and-installingreplacing) .
6. Remove trim for storage tray, refer to «51 16 212 REMOVING AND INSTALLING TRIM FOR CENTER CONSOLE»(ref-202134-S12282838622005102700000) .
7. Remove rear seat, refer to «52 24 005 REMOVING AND INSTALLING OR REPLACING REAR SEAT»(/bmw/m6/e63e64-2005-2010/remont/seats/#seats-repair-instructions-e63__52-24-005-removing-and-installing) .
8. Remove rear cup holder, refer to «51 16 204 REMOVING AND INSTALLING/REPLACING REAR CUP HOLDER»(ref-202134-S10033845712005102700000) .
9. Remove storage compartment, refer to «51 16 200 REMOVING AND INSTALLING STORAGE COMPARTMENT»(ref-202134-S20101411712005102700000) .

Version with telephone

1. Disconnect plug for eject box, refer to «84 11 610 REMOVING AND INSTALLING/REPLACING EJECT BOX (CORDLESS KEYPAD HANDSET)»(ref-202143-S09848676302005102700000) .

Release screws (1).

Disconnect plug connection (2).

Remove interior antenna for comfort access system (3).

Scheme 232

61 35 965 Removing And Installing/Replacing Rear Parcel Antenna For Comfort Access System

Necessary preliminary tasks

1. Remove both trims for roof pillar at rear, refer to «51 43 251 REMOVING AND INSTALLING/REPLACING TRIM PANEL FOR LEFT OR RIGHT REAR ROOF PILLAR (CPILLAR)»(ref-202134-S14331353172005102700000) .
2. Remove rear seat, refer to «52 24 005 REMOVING AND INSTALLING OR REPLACING REAR SEAT»(/bmw/m6/e63e64-2005-2010/remont/seats/#seats-repair-instructions-e63__52-24-005-removing-and-installing) .
3. Remove both rear head restraints, refer to «52 24 390 REMOVING AND INSTALLING / REPLACING REAR HEAD RESTRAINTS»(/bmw/m6/e63e64-2005-2010/remont/seats/#seats-repair-instructions-e63__52-24-390-removing-and-installing) .
4. Remove armrest for rear seat backrest, refer to «52 24 030 REMOVING AND INSTALLING COMPLETE ARMREST FOR REAR SEAT BACKREST»(/bmw/m6/e63e64-2005-2010/remont/seats/#seats-repair-instructions-e63__52-24-030-removing-and-installing) .
5. Remove backrest, refer to «52 24 010 REMOVING AND INSTALLING / REPLACING BACKREST»(/bmw/m6/e63e64-2005-2010/remont/seats/#seats-repair-instructions-e63__52-24-010-removing-and-installing) .
6. Remove both trims for door pillar at top, refer to «51 43 148 REMOVING AND INSTALLING OR REPLACING TRIM ON LEFT OR RIGHT DOOR PILLAR (TOP)»(ref-202134-S27890255172005102700000) .
7. Remove both trims on armrest of side trim, refer to «51 43 ... REMOVING AND INSTALLING/REPLACING TRIM ON ARMREST OF LEFT OR RIGHT SIDE TRIM PANEL»(ref-202134-S20295545592005102700000) .
8. Remove both side trim panels at rear, refer to «51 43 002 REMOVING AND INSTALLING REAR LEFT OR RIGHT SIDE TRIM PANEL»(ref-202134-S17772353712005102700000) .
9. Remove panel for rear window shelf, refer to «51 46 006 REMOVING AND INSTALLING/REPLACING TRIM FOR REAR PARCEL SHELF»(ref-202134-S31938745562005102700000) .

Release screws (1).

Disconnect plug connection (2).

Remove interior antenna for comfort access system (3).

Scheme 233

61 35 970 Removing And Installing/Replacing Luggage Compartment Antenna For Comfort Access System

Necessary preliminary tasks

1. Remove luggage compartment floor trim panel, refer to «51 47 101 REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT FLOOR TRIM PANEL»(ref-202134-S12367961982005102700000) .
2. Remove control unit cover

Disconnect plug connection (1).

Pull luggage compartment antenna (2) for comfort access system from control unit receptacle (3).

Scheme 234

61 35 975 Removing And Installing/Replacing Bumper Antenna For Comfort Access System

Necessary preliminary tasks

1. Partially remove luggage compartment wheel arch trim on left, refer to «51 47 151 REMOVING AND INSTALLING/REPLACING LEFT LUGGAGE COMPARTMENT WHEEL ARCH TRIM»(ref-202134-S33740613502005102700000) .
2. Remove rear bumper trim, refer to «51 12 156 REMOVING AND INSTALLING REAR BUMPER TRIM»(ref-202134-S03823936922005102700000) .

Disconnect plug connection (2).

Press catches (1), feed out bumper antenna for comfort access system (3) in direction of arrow and remove.

Scheme 235

64 11 970 Replacing fogging sensor

Special tools required

Note. For special tools, refer to BODY ELECTRICAL - SPECIAL TOOLS - 645CI (E63) .

1. 00 9 317

Necessary preliminary tasks

1. Remove two-part mirror base cover, refer to «61 35 177 REMOVING AND INSTALLING (REPLACING) RAIN/LIGHT SENSOR»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-35-177-removing-and-installing) .

Unfasten plug connection (1) and disconnect.

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

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

Scheme 236

Installation

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

Clean bonding surface with adhesive remover.

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 less than or equal to 15 N/cm2 onto inside of windshield.

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

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

Scheme 237

RA Diagnosis Programming/Coding

Using the current TIS CD

1. Document type: Select SI Diagnosis Coding.
2. Index number 11: Select Programming Information to display the table of contents.
3. Select the current IDC for the appropriate vehicle.

Place special tool 61 1 153 on relay carrier (1) and carefully pull in direction of arrow until retaining lugs (2) on relay carrier are raised.

Scheme 238

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

Scheme 239

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

Press out double flat spring contact with special tool 61 1 136 or 61 1 137 (ejector).

Scheme 240

For Removing and installing/replacing relay/module, refer to 61 31 470 REMOVING AND INSTALLING/REPLACING RELAY/MODULE .

61 61 ... Adjusting left or right windscreen wiper

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, set the scale value in accordance with the following table.

WIPER ADJUSTMENT SPECIFICATIONS

Scheme 241

61 61 041 Replacing both windshield wiper blades

Fold wiper arm (1) away from windshield.

Press lock (2) and remove wiper blade (3) in direction of arrow.

Installation

Make sure wiper blade (3) is correctly seated.

Scheme 242

Fold wiper arm back onto windshield.

61 61 101 Removing and installing both windshield wiper arms

Special tools required

Note. For special tools, refer to BODY ELECTRICAL - SPECIAL TOOLS - 645CI (E63) .

1. 61 6 060

Installation

Adjust the position of the relevant wiper arm in the wiper rest position.

Measure distance between wiper lip (1) and top edge of cowl panel cover (3) at mounting point (2) of wiper blade.

Adjustment measurements

Scheme 243

1. A: 87 +/- 3 mm
2. B: 69 +/- 3 mm

Removing left wiper arm

Unclip wiper arm cap (1) and remove in direction of arrow.

Scheme 244

Installation

Catches (1) of wiper arm cap (2) must not be damaged.

Make sure wiper arm cap (2) is correctly seated.

Scheme 245

Unscrew nut (1).

Installation

Tightening torque, refer to 61 61 12AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUES - 645CI .

Remove wiper arm (2) in direction of arrow.

Scheme 246

Pull off adjusting disk (1) with special tool 61 6 060.

Installation

Replace adjusting disk (1).

Mount adjusting disk (1) together with wiper arm on shaft.

Check/adjust contact angle of wiper arms to windshield.

Scheme 247

Removing right wiper arm

Remove caps (1).

Scheme 248

Unscrew nuts (1).

Scheme 249

Installation

Tightening torque, refer to 61 61 13AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUES - 645CI .

Detach wiper arm (1) as illustrated with special tool 61 6 060.

Scheme 250

Installation

Check/adjust contact angle of wiper arms to windshield.

61 61 102 Replacing both windshield wiper arms

Necessary preliminary tasks

Remove both windshield wiper arms, refer to 61 61 101 REMOVING AND INSTALLING BOTH WINDSHIELD WIPER ARMS .

Note. If necessary, fit wiper blades on new wiper arms, refer to 61 61 041 REPLACING BOTH WINDSHIELD WIPER BLADES .

61 61 270 Removing and installing console for windshield wiper system completely with motor

Necessary preliminary tasks

1. Remove cowl panel cover.
2. Remove tension strut on spring strut dome, refer to «51 71 373 REMOVING AND INSTALLING/REPLACING TENSION STRUT ON SPRING STRUT DOME»(ref-202134-S35971794602005102700000) .
3. Remove fresh air duct, refer to «64 31 053 REMOVING AND INSTALLING OR REPLACING FRESH AIR DUCT»(/bmw/m6/e63e64-2005-2010/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-31-053-removing-and-installing) .

Release screws (1).

Installation

Tightening torque, refer to 61 61 15AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUES - 645CI .

Remove cross-strut bearing block (2) in direction of arrow.

Scheme 251

Unfasten plug connection (1) and disconnect.

Release screws (A5...A1).

Installation

Insert screws (A1...A5) in specified sequence until hand-tight.

To tighten down screw (A2), if necessary move complete wiper console linkage (2) into reversal position.

Tighten down screws (A1...A5) in specified sequence to tightening torque, refer to 61 61 6AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUES - 645CI .

Scheme 252

Lever out complete wiper console (2) in direction of arrow.

Scheme 253

61 67 010 Removing and installing/replacing washer pump of headlight cleaning system

Release screws (1).

Detach cover (2) from front underride protection (3) and feed out in direction of arrow.

Remove cover (2).

Scheme 254

Note. For purposes of clarity, illustration shows front wheel removed.

Unfasten screws.

Fold back wheel arch trim (1) slightly in direction of arrow.

Scheme 255

Note. Catch any escaping washer fluid if necessary.

Disconnect plug connection (1).

Unlock hose (2) and detach from washer pump of headlight cleaning system (3).

Turn washer pump of headlight cleaning system (3) in direction of arrow and pull upwards out of fluid tank for windshield washer system (4).

Scheme 256

Installation

1. Replace strainer for washer pump of headlight cleaning system.
2. If necessary, coat sealing ring of washer pump for headlight cleaning system with antiseize agent.
3. Ensure hose is laid without kinks.
4. Fill fluid tank for windscreen washer system.

61 67 040 Adjusting spray nozzles for headlight cleaning system

Note. The spray nozzles of the headlight cleaning system have been adjusted at the factory and normally this setting is not altered (except by an accident). The nozzles therefore do not have to be adjusted. The spray nozzles do not have to be adjusted even in the event of replacement as the nozzles themselves and the telescopic nozzle form a single unit (high-pressure nozzle) and are already preset.

61 67 045 Removing and installing/replacing spray nozzles for left or right headlight cleaning system

Necessary preliminary tasks

1. Remove front bumper trim, refer to «51 11 156 REMOVING AND INSTALLING FRONT BUMPER TRIM»(ref-202134-S30125830242005102700000) .

Press lock (2) and detach hose connection (1).

Press catch together in direction of arrow and remove spray nozzle for headlight cleaning system (3) towards bottom.

Scheme 257

Unlock catches (1) of trim (3) through punched holes (2).

Remove trim (3) from above.

Scheme 258

Installation

Following parts of spray nozzle (1) must not be damaged or missing

2 Sealing ring

3 Catch

Catches (3) of trim (4) must not be damaged or missing.

Scheme 259

61 71 015 Removing and installing/replacing a jet nozzle in windshield washer system

Note. The jet nozzles of the windshield washer system are preset at the factory and cannot be readjusted.

Unfasten plug connection (1) and disconnect.

Unlock plug housing (2) and disconnect.

Detach connector (3) in direction of arrow from nozzle of windshield washer system (4).

Unlock nozzle of windshield washer system (4), press out through opening and remove.

Installation

Make sure nozzle of windshield washer system (4) is correctly seated.

Ensure hose is laid without kinks.

Scheme 260

61 71 061 Replacing fluid tank for windscreen washer system

Necessary preliminary tasks

1. If necessary, remove front left wheel, refer to «36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL»(ref-202132-S26430408482005102700000) .
2. Remove windscreen washer pump, refer to «61 71 100 REMOVING AND INSTALLING/REPLACING WINDSCREEN WASHER PUMP»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-71-100-removing-and-installingreplacing) .
3. If necessary, remove washer pump for headlight cleaning system, refer to «61 67 010 REMOVING AND INSTALLING/REPLACING WASHER PUMP OF HEADLIGHT CLEANING SYSTEM»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-67-010-removing-and-installingreplacing) .
4. Remove level switch, refer to «61 31 492 REPLACING LEVEL SWITCH FOR WINDSCREEN WASHER SYSTEM»(/bmw/m6/e63e64-2005-2010/remont/horns/#general-electrical-system-repair__61-31-492-replacing-level-switch) .

Release screws (1).

Feed out air duct (2).

Scheme 261

Release screws (1).

Feed out fluid tank for windscreen washer system (2) slightly in direction of arrow.

Scheme 262

Detach associated filler hose from fitting on fluid tank.

Installation

1. Replace sealing rings and strainers of washer pumps.
2. Coat sealing rings of washer pumps with antiseize agent.
3. Lay lines of washer pumps without kinks and clip into holders on fluid tank.

61 71 100 Removing and installing/replacing windscreen washer pump

Release screws (1).

Detach cover (2) from front underride protection (3) and feed out in direction of arrow.

Scheme 263

Remove cover (2).

Note. For purposes of clarity, illustration shows front wheel removed.

Unfasten screws.

Fold back wheel arch trim (1) slightly in direction of arrow.

Scheme 264

Note. Catch any escaping washer fluid if necessary.

Disconnect plug connection (1).

Detach hose (2) from windscreen washer pump (3).

Pull windscreen washer pump (3) up and out of fluid reservoir for windscreen washer system (4).

Scheme 265

Installation

1. Replace strainer for windscreen washer pump.
2. If necessary, coat sealing ring of windscreen washer pumps with antiseize agent.
3. Ensure hose is laid without kinks.
4. Fill fluid tank for windscreen washer system.

See also:
• GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUES - 645CI
• 52 16 040 REMOVING AND INSTALLING/REPLACING OUTER COVER ON FRONT LEFT OR RIGHT SEAT (SPORTS/ELECTRIC)
• 32 33 001 REMOVING AND INSTALLING / REPLACING STEERING WHEEL
• 32 31 010 REMOVING AND INSTALLING/REPLACING FRONT SECTION OF STEERING COLUMN COVER
• 32 31 020 REMOVING AND INSTALLING / REPLACING LOWER SECTION OF STEERING COLUMN TRIM
• 32 31 004 REMOVING AND INSTALLING / REPLACING UPPER SECTION OF STEERING COLUMN TRIM
• 64 22 137 REMOVING AND INSTALLING/REPLACING LEFT FRESH-AIR GRILL
• 51 16 200 REMOVING AND INSTALLING STORAGE COMPARTMENT
• 32 33 STEERING WHEEL
• 52 14 000 REMOVING AND INSTALLING LEFT OR RIGHT FRONT SEAT (NORMAL/ELECTRIC)
• 52 16 000 REMOVING AND INSTALLING FRONT SEAT (SPORTS/ELECTRIC), LEFT OR RIGHT
• 64 12 ... INITIALIZING INDEPENDENT HEATING REMOTE CONTROL
• 64 22 165 REMOVING AND INSTALLING/REPLACING CENTER FRESH-AIR GRILL
• 52 24 005 REMOVING AND INSTALLING OR REPLACING REAR SEAT
• 52 24 390 REMOVING AND INSTALLING / REPLACING REAR HEAD RESTRAINTS
• 52 24 030 REMOVING AND INSTALLING COMPLETE ARMREST FOR REAR SEAT BACKREST
• 52 24 010 REMOVING AND INSTALLING / REPLACING BACKREST
• 64 31 053 REMOVING AND INSTALLING OR REPLACING FRESH AIR DUCT
• 61 00 ... BATTERY CHARGING
• 61 20 ... BATTERY OPEN-CIRCUIT CURRENT TEST
• 61 13 ... OPENING PLUG HOUSINGS AND REMOVING CONTACTS OF DIFFERENT PLUG SYSTEMS
• 61 00 ... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY
• 61 00 ... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY
• 61 12 ... GENERAL INFORMATION ON INTELLIGENT BATTERY SENSOR (IBS)
• DIAGNOSIS PROGRAMMING/CODING
• 61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD
• 61 31 115 REPLACING ROCKER SWITCH FOR SIDE-WINDOW OPERATION
• 61 00 ... NOTES ON HANDLING OPTICAL FIBERS
• 61 13 CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES
• 61 13 INSTALLING FAN CONNECTOR FOR RETROFITTING/REPAIRS
• 61 13 ... ANTENNA ELBOW PLUG ON RADIO RECEIVER
• 61 13 ... CUTTING OFF, STRIPPING INSULATION AND CUTTING OPTICAL FIBRES TO LENGTH
• 61 13 ... CRIMPING OPTICAL FIBRES
• 61 13 ... CRIMPING MICRO POWER QUADLOCK CONTACTS (MPQ)
• 61 13 ... CRIMPING MICRO QUADLOCK SYSTEM CONTACTS (MQS)
• 61 13 ... REPAIRING RIBBON CABLES
• 61 13 SPECIAL TOOLS FOR WIRING HARNESS REPAIRS
• 61 00 ... BATTERY
• 61 35 ... NOTES ON ESD PROTECTION (ELECTRO STATIC DISCHARGE)
• 61 31 016 REMOVING AND INSTALLING/REPLACING TURN INDICATOR/HEADLIGHT DIPPING SWITCH
• 61 31 040 REMOVING AND INSTALLING/REPLACING SWITCH FOR WINDSHIELD WIPERS
• 61 31 018 REMOVING AND INSTALLING/REPLACING CRUISE CONTROL SWITCH
• steering angle sensor adjustment
• volute spring cassette
• 61 35 015 REMOVING AND INSTALLING (REPLACING) CONTROL UNIT FOR CAR ACCESS SYSTEM
• safety regulations
• 61 31 035 REMOVING AND INSTALLING/REPLACING SWITCH FOR STEERING COLUMN ADJUSTMENT
• decorative trim for multifunction steering wheel switch
• 61 31 192 REPLACING KNOB FOR CONTROLLER
• 61 31 020 REMOVING AND INSTALLING/REPLACING IGNITION STARTER SWITCH
• 61 35 679 INITIALIZING RAIN/LIGHT SENSOR
• 61 31 079 REMOVING AND INSTALLING/REPLACING SWITCH FOR HAZARD WARNING SYSTEM/CENTRAL LOCKING
• 61 31 287 REMOVING AND INSTALLING/REPLACING DRIVING DYNAMICS SWITCH
• 61 35 177 REMOVING AND INSTALLING (REPLACING) RAIN/LIGHT SENSOR
• 61 31 470 REMOVING AND INSTALLING/REPLACING RELAY/MODULE
• 61 61 101 REMOVING AND INSTALLING BOTH WINDSHIELD WIPER ARMS
• 61 61 041 REPLACING BOTH WINDSHIELD WIPER BLADES
• 61 71 100 REMOVING AND INSTALLING/REPLACING WINDSCREEN WASHER PUMP
• 61 67 010 REMOVING AND INSTALLING/REPLACING WASHER PUMP OF HEADLIGHT CLEANING SYSTEM
• 61 31 492 REPLACING LEVEL SWITCH FOR WINDSCREEN WASHER SYSTEM