General Electrical System - Repair BMW Z4 E85/E86

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... Battery

Note. Important notes and instructions for handling batteries can be found in: Battery master document Disconnecting battery Battery charging Welding work 12 00... Instructions On 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).

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, refer to

SI 2 03 98 350 and

SI 2 06 02 854.

If necessary, open existing plugs on the individual cells.

61 0 ...Repairing airbag cables

For safety regulations, see AIR BAG SAFETY PRECAUTIONS . Instructions for disconnecting and connecting battery, see 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 colors. Twist cables again, open length (twist) must not exceed 40 mm. Secure interface (shrink-fit hoses) with insulating tape to prevent cables from twisting open. Instructions for cutting off, insulating, crimping cables, installing and removing contacts

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... Notes on handling optical fibers

Note. The optical fibers are colored differently as follows: Green=MOST (Media Oriented Systems Transport) optical fibers Yellow=ISIS (Intelligent Safety and Integration System) optical fibers Orange=repair optical fibers

Follow instructions for processing cables and optical fibers.

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 11... Notes on front right repair wiring harness (from 10/2003)

Note. When installing the front right repair wiring harness, observe the following: Notes on assignment of repair connectors can be found in the DIS under COMPONENT AND SIGNAL INFORMATION/PLUG, FAN AND SOLDER CONNECTORS. US only: Unpinned cables lead to the Safety and Information Module A150a - pin them in here

61 12 147 Replacing left wiring harness for fully automatic EH convertible top

Necessary preliminary tasks

1. Remove convertible top. See «54 31 015 REPLACING CONVERTIBLE TOP FRAME»(/bmw/z4/e85e86-2002-2005/remont/sun-rooft-topconvertible-top/#convertible-top-hardtop-repair__54-31-015-replacing-convertible-top) .

Note. Remove sheathing of left wiring harness in starting area up to branch.

Wiring harness consists of 3 cable looms

1. Cable loom, hydraulic unit
2. Cable loom, sensors on convertible top main bearing
3. Cable loom, sensor on convertible top catch

Note. Removal of the hydraulic unit cable loom is described in 54 34 005 REMOVING AND INSTALLING/REPLACING HYDRAULIC UNIT FOR CONVERTIBLE TOP DRIVE .

Removing cable loom for sensors on convertible top main bearing

Installation

Make sure sensors on left convertible top main bearing (2) to convertible top frame are correctly positioned.

Release screws (1) and remove sensors on left convertible top main bearing (2).

Scheme 10

Release screw (2).

Remove cable holder (1).

Feed cable loom for sensors on convertible top main bearing (3) out of wiring harness (4).

Scheme 11

Removing cable loom for sensor on convertible top catch

Release screws (1) of front strap on convertible top strip on left.

Feed left front strap (2) out of convertible top strip.

Release the 3 screws of the cable holders behind the convertible top trim and remove the cable holders.

Scheme 12

Pull rubber seal (3) away from frame (2) as illustrated.

Cut through cable band (1) and remove cable loom (4) behind from holder.

Installation

Lay cable loom (4) correctly and use a new cable band.

Make sure rubber seal (3) is correctly installed in groove on frame (2).

Scheme 13

Remove trim on convertible top catch. See 54 34 125 REMOVING AND INSTALLING/REPLACING TRIM ON CONVERTIBLE TOP CATCH .

Release screws (1) and remove cable holder.

Unlock plug connections (3) and disconnect.

Remove adhesive tape (4) and feed cable loom (2) out of convertible top.

Installation

Adhesive tape (4) serves to secure the cable loom (2)".

Scheme 14

61 12 160 Replacing wiring harness for heated rear window

Necessary preliminary tasks

1. Remove convertible top . See «54 31 015 REPLACING CONVERTIBLE TOP FRAME»(/bmw/z4/e85e86-2002-2005/remont/sun-rooft-topconvertible-top/#convertible-top-hardtop-repair__54-31-015-replacing-convertible-top) .

Disconnect plug connection (4).

Feed out cable loom (2) in direction of arrow out of pocket (1).

Release screws (3) and open cable holders (approx. 10 x) along aluminum rail.

Feed out and remove wiring harness for heated rear window.

Scheme 15

Mechanical convertible top only

Cut open cable tie (1).

Release screw (2) and feed out microswitch (3) in direction of arrow.

To simplify this operation, move convertible top (4) into "Close" position slightly.

Installation

Replace cable ties.

Align microswitch.

Scheme 16

Note. Examples of unlocking and disconnecting different plug connections.

Press lock and open clip in direction of arrow.

Disconnect plug connection.

Scheme 17

Press lock and open clip in direction of arrow.

Disconnect plug connection.

Scheme 18

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

Scheme 19

Press lock and disconnect plug connection in direction of arrow.

Scheme 20

Press lock and disconnect plug connection in direction of arrow.

Scheme 21

Press lock and disconnect plug connection in direction of arrow.

Scheme 22

Press lock and disconnect plug connection in direction of arrow.

Scheme 23

Press lock and disconnect plug connection in direction of arrow.

Scheme 24

Press lock and disconnect plug connection in direction of arrow.

Scheme 25

Note. The optical fibers are colored differently as follows: Green=MOST (Media Oriented Systems Transport) optical fibers Yellow=ISIS (Intelligent Safety and Integration System) optical fibers Orange=repair optical fibers

Follow instructions for processing cables and optical fibers.

61 13 Special tools for wiring harness repairs

Special tools required

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

Sourcing reference: BMW Parts.

Scheme 26

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 27

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

Handling

Cutting to length and stripping insulating from cables

Scheme 28

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 mm 2 and for pushing on contact tubes for fan connectors.

Handling

Crimping stop parts (contacts).

Fan connector for retrofitting/repairs.

Scheme 29

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.

Scheme 30

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

Handling

Opening plug housings and removing contacts of different plug systems

Scheme 31

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

Handling

Crimping stop parts (contacts).

Service Information 1 03 89 (037)

Scheme 32

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

1. Cutting to length and stripping insulation from optical fibers
2. Crimping optical fibers
3. Crimping MPQ contacts
4. Crimping MQS contacts

Scheme 33

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

Handling

Repairing ribbon cables.

Scheme 34

Note. Examples of unlocking and disconnecting different plug connections.

Press lock and open clip in direction of arrow.

Disconnect plug connection.

Scheme 35

Press lock and open clip in direction of arrow.

Disconnect plug connection.

Scheme 36

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

Scheme 37

Press lock and disconnect plug connection in direction of arrow.

Scheme 38

Press lock and disconnect plug connection in direction of arrow.

Scheme 39

Press lock and disconnect plug connection in direction of arrow.

Scheme 40

Press lock and disconnect plug connection in direction of arrow.

Scheme 41

Press lock and disconnect plug connection in direction of arrow.

Scheme 42

Press lock and disconnect plug connection in direction of arrow.

Scheme 43

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 44

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 45

Create a loop on inner conductor.

Scheme 46

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 47

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 48

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 49

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

Scheme 50

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 51

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

Special Tools Required

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 52

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 53

Note. Follow procedure for cutting and stripping insulation from cables.

Insert stripped cable (2).

Close pliers (1) fully.

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

Note. Check contact for correct crimping.

Scheme 54

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

Special Tools Required

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 55

Open pliers (1).

Fold up contact carrier (2).

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

Fold back contact carrier (2).

Scheme 56

Note. Follow procedure for cutting and stripping insulation from cables.

Close pliers (1) one notch.

Insert stripped cable (2).

Close pliers (1) fully.

Scheme 57

Open pliers (1).

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

Note. Check contact for correct crimping.

Scheme 58

61 13... Crimping annular contacts

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

Scheme 59

Open crimping pliers (1).

Note. Place contact (2) in designated nest (observe wire crosssection) 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 60

Note. Follow procedure for cutting 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.

Scheme 61

61 13... Crimping optical fibres

Special Tools Required

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 62

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

Scheme 63

Open pliers (2).

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

Scheme 64

Note. Follow procedure for cutting and stripping insulation from optical fibres.

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

Close pliers (3) fully.

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

Remove optical fibre (1).

Scheme 65

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 66

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

Special Tools Required

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 67

Cutting Optical Fibre

Open pliers (1).

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

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

Scheme 68

Stripping Insulation From Optical Fibre

Open pliers (1).

Open lever (2) in direction of arrow.

Scheme 69

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.

Cutting Optical Fibre To Length

Scheme 70

Pull pin (1) in direction of arrow.

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

Scheme 71

Remove blade (1) and replace.

Installation

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

Scheme 72

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 73

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

Abbreviations And What They Mean

ABBREVIATIONS

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 74

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

1. 61 1 200

Socket housing

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

Scheme 75

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

Scheme 76

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

Scheme 77

Pin housing

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

Scheme 78

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

Scheme 79

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 80

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

Scheme 81

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 82

61 13... Repairing ribbon cables

Special Tools Required

1. 61 1 190

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

Scheme 83

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

Close pliers (2).

Scheme 84

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 85

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

Scheme 86

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 87

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 88

Removing MQS contacts from contact carrier

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

Scheme 89

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 90

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 91

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

Scheme 92

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 93

Press lock (1) in direction of arrow.

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

Scheme 94

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 95

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. important notes and instructions for handling batteries can be found in

1. Battery master document
2. «Disconnecting Battery»(/bmw/z4/e85e86-2002-2005/remont/horns/#general-electrical-system-repair__12-00-instructions-for-disconnecting-and)
3. «Battery Charging»(/bmw/z4/e85e86-2002-2005/remont/horns/#general-electrical-system-repair)
4. Welding work
5. «External Jump-Starting Aid»(/bmw/z4/e85e86-2002-2005/remont/horns/#general-electrical-system-repair)

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).

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.

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.

If necessary, open existing plugs on the individual cells.

Battery acid is highly corrosive

Do not allow any battery acid to come into contact with the eyes, the skin or clothing. Therefore wear protective clothing, gloves and goggles.

Do not tilt the battery, acid may emerge from the vent opening.

In event of contact with acid

If acid is splashed into the eyes, rinse them immediately for several minutes with clear water. You must then consult a doctor without delay.

If acid is splashed onto the skin or clothing, neutralize it immediately with a soapy solution and rinse with lots of water.

Seek medical attention immediately if battery acid is accidentally swallowed.

Explosion hazard

Strictly no flames, sparks, naked light or smoking!

A highly explosive mixture of electrolytic gas is created when batteries are charged. The rooms where charging is carried out must therefore always be well ventilated.

Avoid the formation of sparks when handling cables, wiring and electrical devices.

Turn the ignition lock to the 0 position before disconnecting or connecting the battery.

Do not place tools or any similar object on the battery (danger of short-circuiting and explosion!).

61 20... Battery open-circuit current test

Note. Observe safety instructions for handling vehicle battery.

Scheme 96

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

12 00... Instructions for disconnecting and connecting battery

Observe safety instructions for handling vehicle battery. See 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 battery negative terminal from car battery. 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, see 61 21 1AZ in «GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUE»(/bmw/z4/e85e86-2002-2005/remont/horns/#general-electrical-system-tightening-torques) .

After connecting battery

Disconnecting & Connecting Battery Negative Lead

See Battery .

Removing & Installing Battery

See Battery .

Scheme 97

Scheme 98

Scheme 99

61 31 005 Removing and installing/replacing fixture for steering column stalk

Necessary preliminary tasks

1. Remove «STEERING WHEEL»(/bmw/z4/e85e86-2002-2005/remont/steering-column/#steering-column-repair)
2. Remove «UPPER SECTION OF STEERING COLUMN COVER»(/bmw/z4/e85e86-2002-2005/remont/steering-column/#steering-column-repair__upper-section-of-steering-column-cover) and «LOWER SECTION OF STEERING COLUMN COVER»(/bmw/z4/e85e86-2002-2005/remont/steering-column/#steering-column-repair__lower-section-of-steering-column-cover) .

Release screws (1).

Pull back fixture for steering column stalk (2).

Unlock associated plug connections and disconnect.

Remove fixture for steering column stalk (2).

Scheme 100

Do not under any circumstances twist the cover (1) out of its centered position against the fixture for the steering column stalk (2).

Scheme 101

Replacement

Remove Turn Indicator/Headlight Dipping Stalk .

Remove Stalk For Windshield Wipers .

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

Necessary preliminary tasks

1. Remove «Fixture For Steering Column Stalk»(/bmw/z4/e85e86-2002-2005/remont/horns/#general-electrical-system-repair__61-31-005-removing-and-installingreplacing) .
2. E85 only: Remove «Cruise Control Switch»(/bmw/z4/e85e86-2002-2005/remont/horns/#general-electrical-system-repair__61-31-018-removing-and-installingreplacing) .

Press locks (1) and feed direction indicator/dipping stalk (2) in direction of arrow out of Fixture For Steering Column Stalk .

Scheme 102

61 31 018 Removing and installing/replacing cruise control switch

Necessary preliminary tasks

1. Remove «LOWER SECTION OF STEERING COLUMN COVER»(/bmw/z4/e85e86-2002-2005/remont/steering-column/#steering-column-repair__lower-section-of-steering-column-cover) .

Note. For purposes of clarity, the illustration shows the steering wheel removed.

Open lock (1) and feed cruise control switch (2) in direction of arrow out of Fixture For Steering Column Stalk .

Disconnect associated plug connection (4) and remove cruise control switch (2).

Scheme 103

61 31 020 Removing and installing/replacing ignition starter switch

Necessary preliminary tasks

1. Disconnect negative battery lead.
2. Remove «LOWER SECTION OF STEERING COLUMN COVER»(/bmw/z4/e85e86-2002-2005/remont/steering-column/#steering-column-repair__lower-section-of-steering-column-cover) .

Remove sealing varnish and release headless setscrews (1).

Detach ignition starter switch (2) in direction of arrow.

Installation

Secure headless setscrews (1) with sealing varnish.

Open lock (3) in direction of arrow and disconnect plug (4) from ignition starter switch (2).

Scheme 104

61 31 033 Removing and installing/replacing light switch unit

Necessary preliminary tasks

1. Remove finisher on left instrument panel trim «51 16... REPLACING FINISHER ON LEFT INSTRUMENT PANEL»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-replacing-finisher-on-left) .

Release screws (1).

Unlock internal plug connection and disconnect.

Pull out light switch unit (2) in direction of arrow and remove.

Scheme 105

Replacement

Carry out coding/programming.

Observe following IDC specifications

Scheme 106

1. Programming
2. Coding
3. If necessary, car & key memory
4. CD "CIP"

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

Necessary preliminary tasks

1. Remove «Fixture For Steering Column Stalk»(/bmw/z4/e85e86-2002-2005/remont/horns/#general-electrical-system-repair__61-31-005-removing-and-installingreplacing) .

Press locks (1) and windshield wiper stalk (2) in direction of arrow out of fixture for steering column stalk (3).

Scheme 107

61 31 056 Removing and installing/replacing shifters for SMG transmission

Necessary preliminary tasks

1. Remove «DRIVER-SIDE AIR BAG MODULE»(/bmw/z4/e85e86-2002-2005/remont/airbag/#air-bag-restraint-systems) .

Unfasten plug connection (1) and disconnect.

Loosen screws (2).

Note. Both shifters for SMG transmission (3) are connected to each other by wiring harness (4).

Detach both shifters for SMG transmission (3) towards front.

Feed wiring harness (4) out of steering column cover upper section (5) and remove both shifters for SMG transmission (3).

Installation

Make sure wiring harness (4) is correctly routed under steering column cover upper section (5).

Make sure shifters for SMG transmission (3) are correctly seated.

Scheme 108

61 31 057 Removing and installing/replacing switch unit in center console

Open cover (1).

Remove ashtray insert (2) in direction of arrow from center console function carrier (3).

Scheme 109

Unscrew bolt (1).

Unclip side guides (2) and raise center console function carrier (3).

Feed center console function carrier (3) out of front guides (5) and pull back a little.

Unlock associated plug connections, disconnect and remove center console function carrier (3) from center console (4).

Scheme 110

Installation

Make sure front guides (1) of center console function carrier (3) are correctly seated.

Make sure side guides (2) of center console function carrier (3) snap into place correctly.

Scheme 111

Replacement

Unlock plug (1) and unclip in direction of arrow from center console switch unit (4).

Release screws (3) and remove switch unit on center console (4) in direction of arrow from center console function carrier (2).

Scheme 112

61 31 068 Removing and installing/replacing switch for passenger airbag deactivation

Necessary preliminary tasks

1. Remove right fresh-air grille. Use instructions for removing left fresh-air grille. See «64 22 135 REMOVING AND INSTALLING/REPLACING LEFT FRESH AIR GRILLE»(/bmw/z4/e85e86-2002-2005/remont/automatic-hvac-system/#heating-and-air-conditioning-repair__64-22-135-removing-and-installing) .
2. Disconnect negative battery lead.

Unfasten plug connection (1) and disconnect.

Press catches (4) and remove switch for front passenger airbag deactivation (2) in direction of arrow out of instrument panel trim (3).

Installation

Make sure switch for front passenger airbag deactivation (2) is in correct installation position (plug connection (1) at top).

Scheme 113

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

Necessary preliminary tasks

1. Remove trim for preselector lever. See «51 16 210 REMOVING AND INSTALLING/REPLACING TRIM FOR PRESELECTOR LEVER»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-210-removing-and-installingreplacing) .

Press indicator for front passenger airbag deactivation (1) in direction of arrow out of center console (2).

Disconnect plug connection (3) and remove indicator for front passenger airbag deactivation (1).

Scheme 114

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

Necessary preliminary tasks

1. Remove trim for preselector lever. See «51 16 210 REMOVING AND INSTALLING/REPLACING TRIM FOR PRESELECTOR LEVER»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-210-removing-and-installingreplacing) .

Press catches (1) and remove switch for hazard warning flashers/central locking (2) in direction of arrow from trim for preselector lever (3).

Scheme 115

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 116

61 31 115 Replacing rocker switch for side-window operation

This operation is described under

"Replacing switch for wing mirror". See 61 31 255 Replacing Switch For Door Mirror .

61 31 176 Removing and installing/replacing emergency call button

Special tools required

1. 00 9 317

Lever out housing (1) with special tool 00 9 317 as illustrated.

Unlock emergency call button plug connection underneath and disconnect.

Remove complete housing (1) from panel for rear storage box (2).

Scheme 117

Unclip emergency call button (1) in direction of arrow from housing (2) and remove.

Scheme 118

61 31 204 Replacing switch combination for seat adjustment

This operation is described under

"Removing outer cover on front seat". See 52 13 040 REMOVING AND INSTALLING/REPLACING OUTER COVER .

Carry out coding/programming.

Observe following IDC specifications

Scheme 119

1. Programming
2. Coding
3. If necessary, car & key memory
4. CD "CIP"

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

Necessary preliminary tasks

1. Remove «DRIVER-SIDE AIR BAG MODULE»(/bmw/z4/e85e86-2002-2005/remont/airbag/#air-bag-restraint-systems) .

Note. Illustrations show multifunction steering wheel (3) removed.

The two multifunction steering wheel switches (2) can be removed independently of each other.

Release associated screw (1).

Unclip corresponding multifunction steering wheel switch (2) in direction of arrow from multifunction steering wheel (3).

Disconnect associated plug connections and remove multifunction steering wheel switch (2).

Installation

Make sure electrical leads are correctly routed.

Scheme 120

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

Unfasten plug connection (1) and disconnect.

Press catches (2) together and feed hood contact switch (4) in direction of arrow out of fixture (3).

Scheme 121

61 31 255 Replacing switch for door mirror

Special tools required

1. 00 9 317

Fit special tool 00 9 317 as illustrated and lever out switch for door mirror (1).

Feed out switch for wing mirror (1) in direction of arrow from door trim panel (2).

Unlock and disconnect associated plug connections, remove switch for door mirror (1).

Scheme 122

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

If necessary, remove rear underbody protection.

Unfasten plug connection (1) and disconnect. Release switch for reversing light (2).

Scheme 123

61 31 287 Removing and installing/replacing driving dynamics switch

Necessary preliminary tasks

1. Remove trim for preselector lever (shift lever). See «51 16 210 REMOVING AND INSTALLING/REPLACING TRIM FOR PRESELECTOR LEVER»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-210-removing-and-installingreplacing) .

Press driving dynamics switch (1) in direction of arrow out of center console (2).

Disconnect plug connection (3) and remove driving dynamics switch (1).

Scheme 124

61 31 299 Removing and installing/replacing clutch switch module

Necessary preliminary tasks

1. Remove trim panel for pedal assembly. See «51 45 185 REMOVING AND INSTALLING/REPLACING TRIM FOR PEDAL ASSEMBLY»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-45-185-removing-and-installingreplacing) .

Note. For purposes of clarity, the clutch master cylinder is shown removed.

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

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

Scheme 125

Installation

Clutch switch module is secured against incorrect installation.

Clutch switch module must snap audibly into place.

Scheme 126

61 31 310 Replacing brake light switch

Necessary preliminary tasks

1. Remove trim panel for pedal assembly. See «51 45 185 REMOVING AND INSTALLING/REPLACING TRIM FOR PEDAL ASSEMBLY»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-45-185-removing-and-installingreplacing) .

Unfasten plug connection (1) and disconnect.

Pull brake light switch (2) in direction of arrow out of brake light switch holder (4).

Installation

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

Note. Removing brake light switch holder (4)

Press brake pedal (3).

Press catches together and unclip holder for brake light switch (4) from carrier.

Scheme 127

61 31 345 Removing and installing/replacing microswitch for storage box lighting

Necessary preliminary tasks

1. Remove lid on rear storage box. See «51 16 239 REMOVING AND INSTALLING/REPLACING LID ON REAR STORAGE BOX»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-239-removing-and-installingreplacing) .

Lever out cover (1).

Scheme 128

Installation

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

Scheme 129

Remove microswitch for storage box lighting (1) in direction of arrow from fixture (2).

Unlock associated plug connection (3) and disconnect.

Note. If plug connection (3) is not accessible, if necessary release rear screws on center console.

Scheme 130

Replacement

Open clip (1) and remove from microswitch for storage box lighting (2) in direction of arrow.

Installation

Make sure clip (1) is correctly seated.

Scheme 131

61 31 382 Replacing Level Switch For Coolant

Warning! Danger of scalding! Only perform this work after engine has cooled down.

Important! Do not damage connected water hoses. Reposition coolant expansion tank (2) as far as possible until coolant level switch forms the highest point. This will prevent coolant from escaping on opening. If necessary, catch escaping coolant and feed back in later.

Unscrew nuts (1). 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.

Scheme 132

Disconnect plug connection (1) from level switch (2). Turn level switch (2) in direction of arrow, pull downwards out of coolant expansion tank and remove.

Scheme 133

61 31 440 Removing and installing/replacing temperature switch for heated windshield spray jets

Note. Front wheel removed for purposes of clarity.

Unlock fasteners (1) by turning counterclockwise through 180° and fold up cover (2) in direction of arrow.

Scheme 134

Unlock temperature switch for heated windshield spray jets (1) in direction of arrow and press upwards out of cover (2).

Through folded-up cover in wheel arch, unlock and disconnect plug connection of temperature switch for heated windshield spray jets.

Remove temperature switch for heated windshield spray jets (1).

Scheme 135

61 31 492 Replacing level switch for windshield washer system

Note. Front wheel removed for purposes of clarity.

Turn fasteners (1) in direction of arrow through approx. 180°.

Fold up cover (2) in direction of arrow.

Scheme 136

Unlock plug connection (1) and disconnect.

Turn level switch for windshield washing system (2) in direction of arrow through approx. 90° and pull out downwards.

Installation

Make sure level switch for windshield washing system (2) is correctly seated.

Scheme 137

61 31 798 Removing and installing/replacing sensor on left convertible top catch

Necessary preliminary tasks

1. Remove trim on convertible top catch. See «54 34 125 REMOVING AND INSTALLING/REPLACING TRIM ON CONVERTIBLE TOP CATCH»(/bmw/z4/e85e86-2002-2005/remont/sun-rooft-topconvertible-top/#convertible-top-hardtop-repair__54-34-125-removing-and-installingreplacing) .
2. Remove cover. See «54 34 159 REMOVING AND INSTALLING/REPLACING LEFT CONVERTIBLE TOP LATCH»(/bmw/z4/e85e86-2002-2005/remont/sun-rooft-topconvertible-top/#convertible-top-hardtop-repair__54-34-159-removing-and-installingreplacing) .

Unlock plug (1) and detach from housing (2).

Unlock housing (2) and detach in direction of arrow from plug connection (3).

Scheme 138

Release screws (1).

Remove two-part sensor (2) from convertible top catch (3).

Installation

Note different cable lengths of two-part sensor (2).

Scheme 139

61 31 799 Removing and installing/replacing microswitch convertible top compartment

Necessary preliminary tasks

1. Remove center mount for convertible top compartment floor. See «54 31 070 REMOVING AND INSTALLING OR REPLACING BASE PLATE»(/bmw/z4/e85e86-2002-2005/remont/sun-rooft-topconvertible-top/#convertible-top-hardtop-repair__54-31-070-removing-and-installing) .

Detach convertible top compartment microswitch in direction of arrow from center mount for convertible top compartment floor.

Scheme 140

61 31 807 Replacing both sensors on left convertible top main bearing

Necessary preliminary tasks

1. Remove convertible top. See «54 34 120 REPLACING CONVERTIBLE TOP FABRIC»(/bmw/z4/e85e86-2002-2005/remont/sun-rooft-topconvertible-top/#convertible-top-hardtop-repair__54-34-120-replacing-convertible-top) .

Note. Remove sheathing of left wiring harness in starting area up to branch.

Wiring harness consists of 3 cable looms

1. Cable loom, hydraulic unit
2. Cable loom, sensors on convertible top main bearing
3. Cable loom, sensor on convertible top catch

Note. Sensors on left convertible top main bearing (2) can also be replaced individually.

Installation

Make sure sensors on left convertible top main bearing (2) to convertible top frame are correctly positioned.

Release screws (1) and remove sensors on left convertible top main bearing (2).

Scheme 141

Release screw (2).

Remove cable holder (1).

Feed cable loom for sensors on left convertible top main bearing (3) out of wiring harness (4).

Disconnect exposed cable loom for sensors on left convertible top main bearing (3) close to plug connection.

Installation

Wiring is carried out with connectors.

Make sure complete wiring harness (4) is correctly secured.

Scheme 142

Steering Angle Sensor Adjustment

In vehicles with active front steering, steering angle sensor adjustment is integrated in the BMW scan tool service function INITIAL OPERATION/ADJUSTMENT FOR ACTIVE FRONT STEERING and must not be carried out separately.

Note: Steering angle sensor adjustment must be carried out

1. After adjustment work on the front axle/steering
2. After all mechanical work on the steering system
3. 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 33 000 Replacing horn (anti-theft system)

Necessary preliminary tasks

1. Remove rear bumper trim by removing screws at bottom of bumper. Release expansion rivets on left and right of rear wheel housing. Unclip bumper trim on left/right. Pull bumper trim a little rearward and disconnect plug connections on license plate lights. Remove bumper trim with aid of a second person.

Unfasten plug connection (2) and disconnect.

Release nut (1) and remove horn (3) in direction of arrow from mounting (4).

Scheme 143

61 33 040 Removing and installing/replacing a fanfare horn

Note. Front wheel removed for purposes of clarity.

Unlock fasteners (1) by turning counterclockwise through 180° and fold up cover (2) in direction of arrow.

Scheme 144

Unlock plug connection (1) and disconnect.

Release nut (2) and remove air horn complete with holder in direction of arrow.

Scheme 145

Replacement

Unscrew nut (1).

Remove holder (2) from air horn (3).

Scheme 146

Scheme 147

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

Special tools required

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 148

Scheme 149

Touch electrical components by their housings only.

61 35 070 Removing and installing/replacing module for folding door mirror

Necessary preliminary tasks

1. Disconnect battery negative lead.
2. Remove trim for instrument panel, bottom left. See «51 45 181 REMOVING AND INSTALLING/REPLACING TRIM FOR INSTRUMENT PANEL»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-45-181-removing-and-installingreplacing) .

Detach relay carrier (1) in direction of arrow and lay to one side.

Unfasten plug connection (2) and disconnect.

Release nuts (3) and remove module for folding door mirror (4).

Scheme 150

61 35 147 Removing and installing/replacing convertible top module

Special tools required

1. 00 9 323

Necessary preliminary tasks

1. Disconnect and cover battery negative lead.

Lever out cover (1) with special tool 00 9 323 and remove.

Scheme 151

Note. For purposes of clarity, the rear side trim is shown removed.

Unscrew nut (1).

Feed out convertible top module (3) through created opening.

Unlock plug connections (2) and disconnect.

Remove convertible top module (3).

Scheme 152

Replacement

Carry out coding/programming.

Observe following IDC specifications

1. Programming
2. Coding
3. If necessary, car & key memory
4. CD "CIP"

Scheme 153

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.

Scheme 154

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, use BMW scan tool to initialize rain/light sensor.

Scheme 155

Replacement

Carry out programming/coding.

61 35 622 Removing and installing/replacing general module

Necessary preliminary tasks

1. Remove trim for instrument panel, bottom left . See «51 45 181 REMOVING AND INSTALLING/REPLACING TRIM FOR INSTRUMENT PANEL»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-45-181-removing-and-installingreplacing) .

Release screws (1).

Remove general module (3) from instrument panel trim at bottom right (4).

Installation

Make sure general module (3) is correctly seated in guides (2).

Scheme 156

Replacement

Carry out coding/programming.

Observe following IDC specifications

1. Programming
2. Coding
3. If necessary, car & key memory
4. CD "CIP"

Scheme 157

61 35 679 Initializing rain/light sensor

Note. Initialization is necessary: After replacing windshield When installing a used rain/light sensor

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

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

Special Tools Required

1. 61 3 300

Necessary preliminary tasks

1. Remove «UPPER SECTION OF STEERING COLUMN COVER»(/bmw/z4/e85e86-2002-2005/remont/steering-column/#steering-column-repair__upper-section-of-steering-column-cover) .

Slide in special tool 61 3 300 with flattened end (A) facing ring antenna and lever out ring antenna.

Scheme 158

61 35 910 Removing and installing/replacing control unit of electronic immobilizer

Necessary preliminary tasks

1. Disconnect battery negative lead.
2. Remove trim panel for pedal assembly. See «51 45 185 REMOVING AND INSTALLING/REPLACING TRIM FOR PEDAL ASSEMBLY»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-45-185-removing-and-installingreplacing) .

Unfasten plug connection (2) and disconnect.

Release nuts (1) and remove control unit of electronic immobilizer (3).

Scheme 159

Replacement

Carry out coding/programming.

Observe following IDC specifications

1. Programming
2. Coding
3. If necessary, car & key memory
4. CD "CIP"

Scheme 160

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 161

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

Scheme 162

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 163

Scheme 164

61 61 010 Checking/adjusting approach angle of windshield wiper arms on front windscreen

Special tools required

1. 00 9 221
2. 00 9 222
3. 00 9 331

Note. Wiping quality is increased if the approach angle of the windshield wiper arms is precisely adjusted. Before checking contact angle, briefly lift wiper arms off windshield.

Place special tool 00 9 331 in rest position next to pivot point of wiper blade on windshield.

Scheme 165

Contact angle too large (light gap at top between gauge and wiper blade)

Grip wiper arm with special tool 00 9 222 and turn with special tool 00 9 221 in direction of arrow.

Scheme 166

Contact angle too small (light gap at bottom between gauge and wiper blade)

Grip wiper arm with special tool 00 9 222 and turn with special tool 00 9 221 in direction of arrow.

Scheme 167

61 61 041 Replacing Both Windshield Wiper Blades

Press retaining spring in direction of arrow. Pull windshield wiper blade towards wiper arm and feed out. (Scheme 168)

Scheme 168

61 61 100 Removing and installing/replacing both windshield wiper arms

Special tools required

1. 61 6 060

Remove cover (1).

Scheme 169

Release nut (1). For tightening torque, see 61 61 11AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUE .

Scheme 170

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

Scheme 171

If necessary, fit wiper blades on new wiper arms.

Always fit wiper blade with spoiler on left.

Note. The driver's side wiper arm is shown.

Installation

Adjust position of relevant wiper arm in rest position.

The gap between wiper lip (1) and the top edge of cowl panel cover (3) at the attachment point (2) of the wiper blade is measured.

Then tighten down wiper arm and check position of relevant wiper arm again.

Adjustment measurements

Scheme 172

1. Driver's side: 52+/-2 mm
2. Passenger side: 57+/-2 mm

61 61 270 Removing and installing/replacing bracket for windshield wiper system complete with motor

Necessary preliminary tasks

1. Remove cowl panel cover. See «51 13 115 REMOVING AND INSTALLING/REPLACING COWL PANEL COVER»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-13-115-removing-and-installingreplacing) .

Unlock plug connection (1) and disconnect.

Unclip and remove clamping lever (2).

Installation

If necessary, replace clamping lever (2).

Release screws (3).

Installation

Tightening torque = 10 Nm.

Remove wiper bracket (4) upwards.

Scheme 173

Installation

Before fitting the wiper arms, allow the windshield wiper motor to run into the rest position.

To ensure that the windshield wiper system functions properly, check/adjust the contact angle of the wiper arms to the windshield.

Scheme 174

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

Operation is described in

1. Remove fluid reservoir for windshield washer system. . See «61 71 061 Replacing Fluid Reservoir For Windshield Washer System»(/bmw/z4/e85e86-2002-2005/remont/horns/#general-electrical-system-repair__61-71-061-replacing-fluid-reservoir) .

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 67 083 Removing and installing/replacing left or right high-pressure nozzle of headlight cleaning system

Necessary preliminary tasks

1. Remove front bumper trim.

Unlock high-pressure line (1) and detach from high-pressure nozzle of headlight cleaning system (3).

Pull locks (2) in direction of arrow.

Pull high-pressure nozzle of headlight cleaning system (3) in direction of arrow out of guides and feed out through opening in bumper trim.

Installation

Make sure high-pressure nozzle of headlight cleaning system (3) is correctly seated.

New high-pressure nozzle of headlight cleaning system (3) is already preadjusted.

Scheme 175

Gently pull mounts (1) of trim (2) apart in direction of arrow and remove from guide (3).

Installation

Replace trim (2) if mounts (1) are damaged.

Scheme 176

Scheme 177

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

Note. The spray nozzles of the windshield washer system are factory set and cannot be subsequently readjusted.

Unlock plug connection (1) and disconnect.

Detach connecting piece (2) in direction of arrow from spray nozzle of windshield washer system (3).

Unlock spray nozzle (3), press out through opening and remove.

Installation

Make sure spray nozzle of headlight cleaning system (3) is correctly seated.

Ensure hose is laid without kinks.

Scheme 178

61 71 061 Replacing fluid reservoir for windshield washer system

Necessary preliminary tasks

1. Remove windshield washer pump. See «61 71 100 Removing And Installing/Replacing Windshield Washer Pump»(/bmw/z4/e85e86-2002-2005/remont/horns/#general-electrical-system-repair__61-71-100-removing-and-installingreplacing) .
2. Remove level switch for windshield washer system. See «61 31 492 Replacing Level Switch For Windshield Washer System»(/bmw/z4/e85e86-2002-2005/remont/horns/#general-electrical-system-repair__61-31-492-replacing-level-switch) .

Version with headlight cleaning system

Unlock plug connection (1) and disconnect.

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

Installation

Make sure hose (2) is laid without kinks.

All

Release screw (3).

Feed out fluid reservoir for windshield washer system (4) and remove in direction of arrow.

Scheme 179

Installation

Make sure fluid reservoir for windshield washer system (1) is correctly seated in guide (2).

Scheme 180

Version with headlight cleaning system

Withdraw washer pump of headlight cleaning system (1) in direction of arrow.

Installation

Replace sealing ring and strainer in washer pump.

Coat sealing ring of washer pump with antiseize agent.

All

Remove cover for windshield washing reservoir (2) and pull out strainer underneath.

Scheme 181

61 71 100 Removing and installing/replacing windshield washer pump

Note. Drain fluid reservoir for windshield washer system. See 61 71 061 Replacing Fluid Reservoir For Windshield Washer System .

Unlock plug connection (1) and disconnect.

Detach hose (2) from windshield washer pump (4).

Unclip cover (3) and lay to one side.

Installation

Make sure cover (3) is correctly seated.

Make sure hose (2) is laid without kinks.

Turn windshield washer pump (4) in direction of arrow through approx. 90° and pull up and out of fluid reservoir for windshield washer system.

Scheme 182

Installation

Replace sealing ring and strainer in windshield washer pump.

Coat sealing ring of windshield washer pump with antiseize agent.

Fill fluid reservoir for windshield washer system.

See also:
• AIR BAG SAFETY PRECAUTIONS
• 54 31 015 REPLACING CONVERTIBLE TOP FRAME
• 54 34 005 REMOVING AND INSTALLING/REPLACING HYDRAULIC UNIT FOR CONVERTIBLE TOP DRIVE
• 54 34 125 REMOVING AND INSTALLING/REPLACING TRIM ON CONVERTIBLE TOP CATCH
• GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUE
• STEERING WHEEL
• UPPER SECTION OF STEERING COLUMN COVER
• LOWER SECTION OF STEERING COLUMN COVER
• 51 16... REPLACING FINISHER ON LEFT INSTRUMENT PANEL
• DRIVER-SIDE AIR BAG MODULE
• 64 22 135 REMOVING AND INSTALLING/REPLACING LEFT FRESH AIR GRILLE
• 51 16 210 REMOVING AND INSTALLING/REPLACING TRIM FOR PRESELECTOR LEVER
• 52 13 040 REMOVING AND INSTALLING/REPLACING OUTER COVER
• 51 45 185 REMOVING AND INSTALLING/REPLACING TRIM FOR PEDAL ASSEMBLY
• 51 16 239 REMOVING AND INSTALLING/REPLACING LID ON REAR STORAGE BOX
• 54 34 159 REMOVING AND INSTALLING/REPLACING LEFT CONVERTIBLE TOP LATCH
• 54 31 070 REMOVING AND INSTALLING OR REPLACING BASE PLATE
• 54 34 120 REPLACING CONVERTIBLE TOP FABRIC
• 51 45 181 REMOVING AND INSTALLING/REPLACING TRIM FOR INSTRUMENT PANEL
• 51 13 115 REMOVING AND INSTALLING/REPLACING COWL PANEL COVER
• Disconnecting battery
• Battery charging
• 12 00... Instructions On Starting Aid
• BATTERY
• Turn Indicator/Headlight Dipping Stalk
• Stalk For Windshield Wipers
• Fixture For Steering Column Stalk
• Cruise Control Switch
• 61 31 255 Replacing Switch For Door Mirror
• 61 71 061 Replacing Fluid Reservoir For Windshield Washer System
• 61 71 100 Removing And Installing/Replacing Windshield Washer Pump
• 61 31 492 Replacing Level Switch For Windshield Washer System