General Electrical System - Repair BMW Z4 E89

61 20... Battery replacement information

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

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

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

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

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

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

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

Diagnosis system

Register battery replacement

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

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

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

Programming system

1. Battery retrofitting

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

Note. Do not connect the charger to the 12 V charging socket. The 12 V charging socket is supplied with voltage by the rear power distribution box via relay. This relay drops out after terminal 15 OFF. This means that a trickle charger connected at the 12 V charging socket will be disconnected from the battery. Only charge the battery via the jump start terminal point. Only then can the power supply be registered by the vehicle.

Note. Battery draining possible in spite of the intelligent battery sensor IBS being fault-free. A battery can be drained (e.g. with lights or radio switched on) even when the IBS functions perfectly in conjunction with power management. For this reason, only replace the IBS when a corresponding fault entry in the DME or DDE.

61 00... Instructions for disconnecting and connecting battery

Observe SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY .

Before disconnecting battery

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

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

General notes on disconnecting battery

1. Do not disconnect battery leads and leads from alternator and starter motor while engine is running.
2. Cars with IBS on battery negative terminal: Do not under any circumstances pull/lever off pole shoes by force. Do not under any circumstances release socket-head cap screw of IBS.
3. Disconnect terminal of «BATTERY NEGATIVE LEAD»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting) from vehicle 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 installing battery terminal: Tightening torque «61 21 1AZ»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-tightening-torques) .

After connecting battery

61 13... Instructions for opening contacts and locks of different plug contact systems

ABBREVIATIONS OF PLUG CONTACTS SYSTEM CHART

Scheme 52

Note. Special tools referred to in the repair instructions below are contained in the following special tool kits: Release and pressing-off tool61 1 150 will be replaced on 09/2005 by 61 0 300 (BMW) and 61 0 400 (MINI) Release and pressing-off tool 61 1 100 (engine)

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

61 00... Notes on handling optical fibres

Note. The optical fibres are colored differently as follows: Green = MOST ( M edia O riented S ystems T ransport) fibre-optic cables Yellow = ISIS ( I ntegrated S ervice I nformation S erver) optical fibres Orange=repair fibre-optic cables Follow instructions for processing cables and optical fibres See 6113... CUTTING OFF, STRIPPING INSULATION AND CUTTING OPTICAL FIBRES TO LENGTH or 6113... CRIMPING OPTICAL FIBRES .

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

The following applies in general

To avoid damage, observe the following instructions

1. Avoid compressive and tensile loads
2. To ensure professional repairs, perform repair work only with BMW-approved or recommended special tools and spare parts
3. Make sure cables are laid without kinks or abrasions
4. Ensure non-contacting routing at sharp-edged body parts; use edge protection if necessary
5. Secure additionally laid cables/leads with cable ties

The following additionally applies

Shielded lines (coaxial lines)

Fibre-optic cable

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

Treating cables and fibre-optic cables See 6113... CUTTING OFF, STRIPPING INSULATION AND CUTTING OPTICAL FIBRES TO LENGTH or 6113... CRIMPING OPTICAL FIBRES

FlexRay

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

Note. FlexRay lines may only reveal one separation point (bride); renew complete line if necessary The cable is a twisted cable. If possible, maintain twisted cable after repair

Airbag lines

REPAIRING AIRBAG CABLES

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

Do not start the engine with help of starting sprays.

Preparation

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

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

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

Operation

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

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

Risk of explosion!

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

61 00... Repairing airbag cables

Safety regulations

Safety regulations for handling components of airbag system.

INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .

Procedure for cable repair

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

Observe safety precautions when working on MSA vehicles

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

MSA function is deactivated by

Scheme 53

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

Scheme 54

1. Workshop mode A = 10 mm
2. Basic setting (engine hood/bonnet open) B = 7 mm To make sure that the engine hood/bonnet contact is at the basic setting, if necessary press the hood/bonnet contact up to the limit position before starting work and slowly release.

When working with diagnosis tools

1. Observe instructions in diagnosis tool

61 00... Safety instructions for handling vehicle battery

Battery acid is highly corrosive

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

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

In event of contact with acid

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

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

Seek medical attention immediately if battery acid is accidentally swallowed.

Explosion hazard

Strictly no flames, sparks, naked light or smoking!

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

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

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

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

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

Subject of repair instructions

1. «SPECIAL TOOLS FOR WIRING HARNESS REPAIRS»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-13-special-tools-for-wiring)
2. «CUTTING CABLES TO LENGTH AND STRIP INSULATION»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-13-cutting-to-length-and)
3. Crimping stop parts (contacts) . See «6113... CRIMPING MICRO QUADLOCK SYSTEM CONTACTS (MQS)»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-13-crimping-micro-quadlock-system) ; «6113... CRIMPING MICRO POWER QUADLOCK CONTACTS (MPQ)»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-13-crimping-micro-power-quadlock) or «6113... CRIMPING STOP PARTS»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-13-crimping-stop-parts)
4. «BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-13-butt-connector-for-repairing)
5. «COMB CONNECTOR FOR RETROFITTING/REPAIRS»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-13-installing-fan-connector-for)
6. «CUTTING TO LENGTH AND STRIPPING INSULATION FROM OPTICAL FIBRES»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-13-cutting-off-stripping-insulation) «CRIMPING OPTICAL FIBRES»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-13-crimping-optical-fibres)

The following applies in general

To avoid damage, observe the following instructions

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

The following additionally applies

Shielded lines

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

Coaxial line

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

CVBS lines

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

HSD lines

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

Optical fibre cable

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

Treating cables and optical fibre cables

FlexRay

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

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

Airbag lines

Repairing airbag cables

Ribbon cables

Repairing ribbon cables Z

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

Read and comply with NOTES ON HANDLING WIRING HARNESSES AND WIRING !

Read and comply with NOTES ON CRIMPING STOPS!

Necessary preliminary work

Remove GLOVEBOX .

Remove JUNCTION BOX

Work is shown on the E90 by way of example.

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

Disconnect plug connection (1).

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

Release screws (3).

Scheme 55

Disconnect the positive battery cable (2).

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

Scheme 56

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

Scheme 57

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

Scheme 58

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

Scheme 59

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

Scheme 60

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

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

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

Scheme 61

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

Scheme 62

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

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

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

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

Scheme 63

Mount the cap (1) flush.

Scheme 64

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

Scheme 65

Note. Do not connect the charger to the 12 V charging socket. The 12 V charging socket is supplied with voltage by the rear power distribution box via relay. This relay drops out after terminal 15 OFF. This means that a trickle charger connected at the 12 V charging socket will be disconnected from the battery. Only charge the battery via the jump start terminal point. Only then can the power supply be registered by the vehicle.

Note. Battery draining possible in spite of the intelligent battery sensor IBS being fault-free. A battery can be drained (e.g. with lights or radio switched on) even when the IBS functions perfectly in conjunction with power management. For this reason, only replace the IBS when a corresponding fault entry in the DME or DDE.

ABBREVIATIONS OF PLUG CONTACTS SYSTEM CHART

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

61 12 013 Replacing battery negative lead

Necessary preliminary tasks

1. Remove «PANEL FOR LUGGAGE COMPARTMENT SIDE MEMBER»(ref-381258-S22161980252010122800000)

Loosen nut (1).

Tightening torque 61 21 1AZ .

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

Unfasten plug connection (2) and disconnect.

Release nut (3) and battery negative lead (4).

Tightening torque 61 12 5AZ .

Scheme 66

61 12 002 Replacing battery positive lead

Necessary preliminary tasks

1. Clamp off «BATTERY NEGATIVE LEAD»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting)

Unlock and disconnect plug connection for safety battery terminal (1).

Loosen nut (2).

Tightening torque 61 21 1AZ .

Unscrew nut (3).

Tightening torque 61 12 1AZ

Release attachment point (4).

Release screw (5).

Tightening torque 61 12 3AZ .

Disconnect battery positive lead (6).

Scheme 67

Installation

Make sure battery positive lead (6) is correctly routed.

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

Necessary preliminary tasks

1. Remove «LUGGAGE COMPARTMENT FLOOR TRIM PANEL»(ref-381258-S02647489252010122800000)
2. Disconnect «BATTERY NEGATIVE LEAD»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting)

Release screw (1).

Tightening torque 61 12 3AZ .

Unfasten plug connection (2) and disconnect.

Scheme 68

Feed out vacuum hose (1).

Release nuts (2).

Release all screws.

Remove heat shield (3) towards bottom.

Scheme 69

Feed out battery positive leads (1) towards bottom.

Scheme 70

Unscrew nuts (1).

Release cable tie and remove cover (2).

Scheme 71

Release cable holder (1).

Scheme 72

Unscrew nuts (1).

Remove duct cover (2).

Scheme 73

Release cable holder (1).

Scheme 74

Release screws (1).

Remove electronics box cover (2).

Scheme 75

Unfasten plug connection (1) and disconnect.

Remove battery positive lead with wiring harness grommet (2) from electronics box.

Installation

Make sure wiring harness grommets (2) are correctly seated in electronics box.

Scheme 76

Remove cover cap (1) from B+ terminal.

Scheme 77

Slacken nut (1).

Tightening torque 61 12 2AZ .

Remove battery positive lead in downward direction.

Scheme 78

61 12 062 Replacing wiring harness for front bumper

Necessary preliminary tasks

1. Remove front bumper trim See «5111156 REMOVING AND INSTALLING FRONT BUMPER TRIM»(ref-381258-S34243602582010122800000) or «5111157 REPLACING FRONT BUMPER TRIM»(ref-381258-S06724060582010122800000) .

Unlock and disconnect plug connections (1) of all four ultrasonic transducers.

Unclip wiring harness (2) from bumper trim (3).

Remove wiring harness (2) from bumper trim (3).

Remove PDC See 6620518 REMOVING AND INSTALLING/REPLACING A FRONT ULTRASONIC TRANSDUCER (SIDE) or 6620520 REMOVING AND INSTALLING/REPLACING A FRONT ULTRASONIC TRANSDUCER (MIDDLE) .

Installation

Make sure wiring harness (2) is laid correctly.

Scheme 79

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

Necessary preliminary tasks

1. Close front side window completely
2. Remove «FRONT DOOR TRIM»(ref-381258-S10582091432010122800000)
3. Remove «SOUND INSULATION IN FRONT DOOR»(ref-381258-S21142958842010122800000)

Release screws (1).

Disconnect plug connections (2).

Cut open cable fastener (3).

Remove speaker holder (4).

Installation

Make sure door wiring harness is correctly laid.

Scheme 80

Release cable tie (1).

Unfasten plug connection (2) and disconnect.

Installation

Replace cable tie (1).

Scheme 81

Note. Front side panel shown removed for purposes of clarity.

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) in direction of arrow out of front door (4).

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

Scheme 82

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

Note. The repair range IV for vehicle electrical system contained the required special tools and individual parts for retrofitting and repair work with the aid of fan connectors. The case can no longer be ordered. Order individual parts for wiring harness repair through BMW Parts Service.

Scheme 83

Choose repair kit.

Example: Repair kit, circular plug system D 2.5.

Scheme 84

Remove following parts

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

Scheme 85

Open secondary lock on housing.

Mark damaged contact (4) with socket number of housing and press it out of housing using appropriate special tool contained in special tool kit 61 0 300.

See repair instructions

INSTRUCTIONS FOR OPENING CONTACTS AND LOCKS of different plug contact systems.

Scheme 86

Scheme 87

Adhere to following procedure

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

Refer also to repair instruction

CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES

Crimp butt connector on preassembled wire end.

Special tools

1. 61 4 328 (0.35 - 2.5 mm 2
2. 61 0 240 (4.0 - 6.0 mm 2

See repair instructions

CRIMPING ON STOP PARTS

Scheme 88

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

Scheme 89

Crimp unused wire end to butt connector.

Scheme 90

Pull shrink-on sleeve over butt connector.

Scheme 91

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

Insert contact in housing.

Close secondary lock on housing.

Scheme 92

61 13... Circular connector, 7-pin, 8-pin, system D2.5

Carefully pull off rubber grommet (1).

Carefully press back retaining lugs (2) of internal connector (3).

Scheme 93

Slide internal connector (3) in direction of arrow until retaining lugs (2) lock into locking groove (4).

Scheme 94

Use special tool 61 0 303 (61 1 132) to press back retaining hook (5) of corresponding contact and pull out cable with contact.

Scheme 95

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

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

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

Scheme 96

Open hand pliers (1).

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

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

Close hand pliers (1) one notch.

Scheme 97

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

Insert stripped cable (2).

Close hand pliers (1) fully.

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

Scheme 98

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

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

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

Scheme 99

Open pliers (1).

Fold up contact carrier (2).

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

Fold back contact carrier (2).

Scheme 100

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

Close pliers (1) one notch.

Insert stripped cable (2).

Close pliers (1) fully.

Scheme 101

Open pliers (1).

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

Scheme 102

61 13... Crimping optical fibres

Special tools required

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 103

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

Scheme 104

Open pliers (2).

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

Scheme 105

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 106

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 107

61 13... Crimping stop parts

Necessary preliminary work

1. Cut cables to length and strip insulation

Special tools for wiring harness repairs.

Spare parts for vehicle electrical system (stop parts and housings)

1. Sourcing reference: BMW Parts Service.

1. Crimping stop parts up to 2.5 mm 2

Crimping Micro Quadlock System contacts (MQS).

1. Special tool 61 4 320

Crimping Micro Power Quadlock contacts (MPQ).

1. Special tool 61 4 325

Crimping miscellaneous stop parts up to 2.5 mm 2

1. Special tool 61 4 328

2. Crimping stop parts including and over 2.5 mm 2

Crimping load current contacts (LSK 8).

1. Special tool 61 0 210

Crimping SLK 2.8.

1. Special tool 61 0 220

Crimping double spring contact (DFK 40)

Crimping MAK 8

1. Special tool 61 0 230

Checking crimping

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

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

Scheme 108

Correct crimping

Visible conductor end (10).

Visible insulation end (11).

Scheme 109

Incorrect crimping

Conductor end (10) inserted too far.

Insulation end (11) in wire crimp.

If necessary, repeat crimping with a new contact.

Scheme 110

Incorrect crimping

Conductor end (10) not visible.

Insulation end (11) not visible.

If necessary, repeat crimping with a new contact.

Scheme 111

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

To cut off, strip insulation and cut optical fibres to length, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 322 (2) 61 4 320 from crimping set.

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

Scheme 112

Cutting optical fibre

Open pliers (1).

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

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

Scheme 113

Stripping insulation from optical fibre

Open pliers (1).

Open lever (2) in direction of arrow.

Scheme 114

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 115

Cutting optical fibre to length

Pull pin (1) in direction of arrow.

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

Scheme 116

Remove blade (1) and replace.

Installation

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

Scheme 117

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 118

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

Stripped length

STRIPPED LENGTH REFERENCE CHART

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

Note. The repair range IV for vehicle electrical system contained the required special tools and individual parts for retrofitting and repair work with the aid of fan connectors. The case can no longer be ordered. Order individual parts for wiring harness repair through BMW Parts Service.

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

Scheme 119

Alternatively

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

Scheme 120

Cut through wire loop in wiring harness at established point.

Strip insulation from both wire ends.

See repair instructions

CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES

Crimp contact sleeves on both wire ends.

See repair instructions

CRIMPING ON STOP PARTS

Note. If using repair kit for contact sleeves, refer to repair instruction

BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION .

Scheme 121

Crimp connecting cable for retrofitting likewise with contact sleeve.

Scheme 122

Cut required number of poles to length for fan connectors.

Scheme 123

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

See repair instructions

SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

Scheme 124

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 125

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

Scheme 126

Attach wire with contact sleeve to fan connector.

Scheme 127

Press crimping tool together and slide contact sleeve firmly home.

Scheme 128

Push on further contact sleeves for potential branching.

Scheme 129

Installation in wet area (engine compartment, wheel arch)

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

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

Note. Ensure that fan connector has sufficient contact surface on mounting point. Do not heat shrink-fit hose on edges of fan connector too strongly, risk of cracking.

Scheme 130

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 131

ABBREVIATIONS OF PLUG CONTACTS SYSTEM CHART

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

Note. The optical fibres are colored differently as follows: Green = MOST ( M edia O riented S ystems T ransport) fibre-optic cables Yellow = ISIS ( I ntegrated S ervice I nformation S erver) optical fibres Orange=repair fibre-optic cables Follow instructions for processing cables and optical fibres See 6113... CUTTING OFF, STRIPPING INSULATION AND CUTTING OPTICAL FIBRES TO LENGTH or 6113... CRIMPING OPTICAL FIBRES .

The following applies in general

To avoid damage, observe the following instructions

1. Avoid compressive and tensile loads
2. To ensure professional repairs, perform repair work only with BMW-approved or recommended special tools and spare parts
3. Make sure cables are laid without kinks or abrasions
4. Ensure non-contacting routing at sharp-edged body parts; use edge protection if necessary
5. Secure additionally laid cables/leads with cable ties

The following additionally applies

Shielded lines (coaxial lines)

Fibre-optic cable

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

Treating cables and fibre-optic cables See 6113... CUTTING OFF, STRIPPING INSULATION AND CUTTING OPTICAL FIBRES TO LENGTH or 6113... CRIMPING OPTICAL FIBRES

FlexRay

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

Note. FlexRay lines may only reveal one separation point (bride); renew complete line if necessary The cable is a twisted cable. If possible, maintain twisted cable after repair

Airbag lines

REPAIRING AIRBAG CABLES

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

Necessary preliminary tasks

1. Remove «FOOTWELL SIDE TRIM PANEL ON A-PILLAR, LEFT»(ref-381258-S27207877612010122800000)

Release screws (1).

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

Scheme 132

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

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

Insert special tool 61 0 315 in OBD-II socket (1) in direction of arrow and press out associated flat spring contact (4). Press remaining flat spring contacts with special tool 61 0 315 out of OBD-II socket (1).

Scheme 133

Installation

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

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

61 13 050 Removing and installing/replacing fuse box in passenger compartment

Necessary preliminary tasks

1. Remove «JUNCTION BOX ELECTRONICS»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-35-107-removing-and-installing) .

Unlock plug connections (1) on passenger compartment fuse box (2) and disconnect.

Release cable tie (3).

Release screw (4).

Fold down passenger compartment fuse box (5) in direction of arrow.

Scheme 134

Unlock plug connections (1) and disconnect.

Scheme 135

Release screws (1).

Unlock retainer (2) and remove passenger compartment fuse box (3).

Scheme 136

Replacement

Remove JUNCTION BOX ELECTRONICS .

Remove fuses.

Safety regulations

Safety regulations for handling components of airbag system.

INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .

61 13... Special tools for wiring harness repairs

Release and press-out tool

1. Special tool 61 0 300
2. Special tool 61 0 400 (MINI N12/N14)
3. Special tool 61 1 100 (engine)

Handling

1. «INSTRUCTIONS FOR OPENING CONTACTS AND LOCKS»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-13-instructions-for-opening-contacts) of different plug contact systems

Scheme 137

Cutting to length and stripping insulation from cables

Wire stripper MultiStrip10

Handling

1. «CUTTING CABLES TO LENGTH AND STRIP INSULATION»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-13-cutting-to-length-and)

Crimping stop parts (small contacts) and butt connectors

1. Special tool 61 4 320

Scheme 138

1. Tool without crimping head
2. Crimping head «(STRIPPING INSULATION AND CUTTING FIBRE-OPTIC CABLES TO LENGTH)»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-13-cutting-off-stripping-insulation)
3. Crimping head «(CRIMPING FIBRE-OPTIC CABLE CONTACTS)»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-13-crimping-optical-fibres)
4. Crimping head «(CRIMPING MQS CONTACTS)»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-13-crimping-micro-quadlock-system)
5. Crimping head «(CRIMPING MPQ CONTACTS)»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-13-crimping-micro-power-quadlock)
6. Replacement blade (face-cutting fibre-optic cables)
7. Replacement blade with tool (insulation stripping unit)
8. Universal crimping head

Crimping stop parts (large contacts) and butt connectors

1. Special tool 61 0 200 (crimping set)
2. Special tool 61 0 210 (matrix set SLK 8)
3. Special tool 61 0 220 (matrix set SLK 2.8)
4. Special tool 61 0 230(matrix set MAK 8/DFK4)
5. Special tool 61 0 240 x (butt connector 4.0 - 6.0 mm 2 )

Scheme 139

Subject of repair instructions

1. «SPECIAL TOOLS FOR WIRING HARNESS REPAIRS»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-13-special-tools-for-wiring)
2. «CUTTING CABLES TO LENGTH AND STRIP INSULATION»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-13-cutting-to-length-and)
3. Crimping stop parts (contacts) See «6113... CRIMPING MICRO QUADLOCK SYSTEM CONTACTS (MQS)»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-13-crimping-micro-quadlock-system) ; «6113... CRIMPING MICRO POWER QUADLOCK CONTACTS (MPQ)»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-13-crimping-micro-power-quadlock) or «6113... CRIMPING STOP PARTS»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-13-crimping-stop-parts)
4. «BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-13-butt-connector-for-repairing)
5. «COMB CONNECTOR FOR RETROFITTING/REPAIRS»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-13-installing-fan-connector-for)
6. «CUTTING TO LENGTH AND STRIPPING INSULATION FROM OPTICAL FIBRES»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-13-cutting-off-stripping-insulation) «CRIMPING OPTICAL FIBRES»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-13-crimping-optical-fibres)

6113... 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 140

Press lock and open clip in direction of arrow.

Disconnect plug connection.

Scheme 141

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

Scheme 142

Press lock and disconnect plug connection in direction of arrow.

Scheme 143

Press lock and disconnect plug connection in direction of arrow.

Scheme 144

Press lock and disconnect plug connection in direction of arrow.

Scheme 145

Press lock and disconnect plug connection in direction of arrow.

Scheme 146

Press lock and disconnect plug connection in direction of arrow.

Scheme 147

Press lock and disconnect plug connection in direction of arrow.

Scheme 148

Press the lock and detach plug connection.

Scheme 149

Press the lock and detach plug connection.

Scheme 150

Press the lock on both sides and detach plug connection.

Scheme 151

Press the lock and detach plug connection.

Scheme 152

61 14 010 Removing and installing/replacing distribution box

Necessary preliminary tasks

1. Clamp off «BATTERY NEGATIVE LEAD»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting)

Unscrew nuts (1).

Tightening torque 61 12 1AZ .

Unlock plug connections (2) and disconnect.

Unlock retaining clip (3).

Remove distribution box (4) in direction of arrow.

Installation

Make sure distribution box (4) is correctly seated.

Scheme 153

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

Necessary preliminary tasks

1. Read fault memory.
2. Clamp off «BATTERY NEGATIVE LEAD»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting)

Remove cover (1).

Unscrew nuts (1).

Tightening torque 61 12 4AZ .

Disconnect battery positive leads (2).

Release screw (3).

Remove B+ terminal.

Scheme 154

Scheme 155

Introduction

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

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

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

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

Service life of AGM batteries

Scheme 156

SERVICE LIFE OF AGM BATTERIES DESCRIPTION CHART

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

Brief component description

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

Scheme 157

AGM BATTERY COMPONENTS DESCRIPTION CHART

Construction

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

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

How it works

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

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

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

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

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

Notes for Service department

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

Charging

Installation location

Housing

61 20... AGM battery

Introduction

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

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

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

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

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

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

Service life of AGM batteries

Scheme 158

AGM BATTERIES DESCRIPTION CHART

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

Brief component description

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

AGM BATTERY COMPONENTS DESCRIPTION CHART

Construction

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

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

How it works

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

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

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

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

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

Notes for Service department

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

Charging

Installation location

Housing

Battery renewal

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

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

61 20... Battery charge

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

If necessary, open existing seal plugs on the individual cells.

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

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

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

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

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

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

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

Diagnosis system

Register battery replacement

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

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

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

Programming system

1. Battery retrofitting

61 20 900 Disconnecting and connecting battery negative lead

Necessary preliminary tasks

1. Remove «FRONT LUGGAGE COMPARTMENT FLOOR TRIM PANEL»(ref-381258-S02647489252010122800000)

Loosen nut (1).

Tightening torque 61 21 1AZ .

Detach battery negative lead with IBS towards top, lay to one side and secure.

Scheme 159

Via BMW diagnosis system

Carry out STEERING ANGLE SENSOR ADJUSTMENT .

Note. Do not connect the charger to the 12 V charging socket. The 12 V charging socket is supplied with voltage by the rear power distribution box via relay. This relay drops out after terminal 15 OFF. This means that a trickle charger connected at the 12 V charging socket will be disconnected from the battery. Only charge the battery via the jump start terminal point. Only then can the power supply be registered by the vehicle.

Note. Battery draining possible in spite of the intelligent battery sensor IBS being fault-free. A battery can be drained (e.g. with lights or radio switched on) even when the IBS functions perfectly in conjunction with power management. For this reason, only replace the IBS when a corresponding fault entry in the DME or DDE.

Observe SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY .

Before disconnecting battery

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

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

General notes on disconnecting battery

1. Do not disconnect battery leads and leads from alternator and starter motor while engine is running.
2. Cars with IBS on battery negative terminal: Do not under any circumstances pull/lever off pole shoes by force. Do not under any circumstances release socket-head cap screw of IBS.
3. Disconnect terminal of «BATTERY NEGATIVE LEAD»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting) from vehicle 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 installing battery terminal: Tightening torque «61 21 1AZ»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-tightening-torques) .

After connecting battery

Do not start the engine with help of starting sprays.

Preparation

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

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

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

Operation

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

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

Risk of explosion!

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

Battery acid is highly corrosive

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

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

In event of contact with acid

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

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

Seek medical attention immediately if battery acid is accidentally swallowed.

Explosion hazard

Strictly no flames, sparks, naked light or smoking!

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

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

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

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

61 20 005 Testing battery with battery tester

Necessary preliminary tasks

1. Remove «LUGGAGE COMPARTMENT FLOOR TRIM PANEL»(ref-381258-S02647489252010122800000)

Scheme 160

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

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

61 20 503 Vehicle battery - closed-circuit current monitoring

Necessary preliminary work

1. Clamp off «BATTERY NEGATIVE LEAD»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting)
2. Disconnect Both negative battery cables

Connect adapter for closed-circuit current measurement.

Connect BMW diagnosis system.

Measure closed-circuit current.

61 21 028 Charge battery

Note. Use BMW-recommended charging computers to charge the battery.

61 21 010 Removing and installing or replacing battery

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

Necessary preliminary tasks

1. Remove «LUGGAGE COMPARTMENT FLOOR TRIM PANEL»(ref-381258-S02647489252010122800000)
2. Clamp off «BATTERY NEGATIVE LEAD»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting)

Release screw (1) and remove bracket (2).

Scheme 161

Slacken nut (1).

Tightening torque 61 21 1AZ .

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

Detach vent hose (3).

Scheme 162

Release screw (4) and remove bracket (5).

Lift out battery.

Installation

Make sure battery is correctly seated in associated fixture.

Replacement

1. Read out fault memory, clear if necessary
2. On vehicles with IBS (intelligent battery sensor) «REGISTER BATTERY REPLACEMENT»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-20-battery-replacement-information)

61 21 028 Testing battery with battery tester

Necessary preliminary work

Remove LUGGAGE COMPARTMENT FLOOR TRIM PANEL .

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

Procedure

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

61 31 996 Carrying 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 disconnection of battery after replacement/coding/programming of the following components: Fixture for switches of steering column/switch cluster/steering angle sensor Dynamic Stability Control (DSC) control unit

Connect vehicle to BMW diagnosis system.

Select and carry out steering angle sensor adjustment under Service functions.

Scheme 163

Scheme 164

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

Necessary preliminary tasks

1. Clamp off «BATTERY NEGATIVE LEAD»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting)

Carefully lever out side cover (1) with special tool 00 9 323 at points (2).

Scheme 165

Disconnect plug connection (1).

Unlock catches (4) in direction of arrow.

Feed switch for passenger airbag deactivation (2) out of side cover (3).

Scheme 166

Installation

Make sure switch for passenger airbag deactivation (2) is correctly seated in side cover (3).

61 31 052 Removing and installing center console control panel

Necessary preliminary tasks

1. Remove «TRIM FOR STORAGE COMPARTMENT»(ref-381258-S22067486212010122800000)

Unclip center console control panel (1) at points (2).

Remove center console control panel (1) from storage compartment (3).

Installation

Make sure center console control panel (1) is correctly engaged.

Scheme 167

61 31 133 Removing and installing/replacing AV connection socket

Necessary preliminary tasks

1. Remove «TRIM FOR STORAGE COMPARTMENT»(ref-381258-S22067486212010122800000)

Remove rear cover (1) from center console (2) in direction of arrow.

Disconnect plug connection underneath.

Scheme 168

Unscrew nuts (1).

Release screw (2).

Raise center console (3) a little.

Open center console storage compartment lid (4).

Scheme 169

Press connection socket (1) outwards out of center console (2).

Scheme 170

Unlock plug connections (1) and disconnect.

Remove connection socket (2).

Installation

Make sure connection socket (1) is correctly seated.

Retaining lugs (3) must not be damaged.

Scheme 171

61 31 243 Removing and installing/replacing Hall switch

Necessary preliminary tasks

1. Remove «PANEL FOR LUGGAGE COMPARTMENT SIDE MEMBER ON LEFT»(ref-381258-S26469375022010122800000)

Disconnect plug connection (1).

Unlock Hall switch (2) and in remove in direction of arrow.

Scheme 172

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

Necessary preliminary tasks

1. Remove «RIGHT INSTRUMENT PANEL TRIM»(ref-381258-S13175965192010122800000)

Unlock retainer (1) on both sides.

Remove Start/Stop switch (2).

Scheme 173

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

Necessary preliminary tasks

1. Remove «TRIM FOR STORAGE COMPARTMENT»(ref-381258-S22067486212010122800000)

Remove rear cover (1) from center console (2) in direction of arrow.

Disconnect plug connection underneath.

Unscrew nuts (1).

Release screw (2).

Raise center console (3) a little.

Open center console storage compartment lid (4).

Press connection socket (1) outwards out of center console (2).

Unlock plug connections (1) and disconnect.

Remove connection socket (2).

Installation

Make sure connection socket (1) is correctly seated in center console (2).

Retaining lugs (3) must not be damaged.

61 31 113 Removing and installing/replacing both shift paddles for automatic transmission

Necessary preliminary tasks

1. Remove «BOTH SWITCHES FROM SPORT STEERING WHEEL»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-31-229-removing-and-installingreplacing)

Note. For purposes of clarity. Illustration shows steering wheel removed.

Release screws (1).

Disconnect plug connections (2).

Remove shift paddles for automatic transmission (3) in direction of travel.

Scheme 174

Installation

Make sure electrical leads are correctly routed.

Make sure shift paddles for automatic transmission (3) are correctly seated on steering wheel.

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

Necessary preliminary tasks

1. Remove «AIRBAG UNIT»(/bmw/z4/e89-2009-2013/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-34-030-removing-and-installingreplacing)

Note. Both multifunction steering wheel switches (4) are connected to each other by the wiring harness (3).

Unfasten plug connection (1) and disconnect.

Unfasten screws (2).

Feed wiring harness (3) out of steering wheel.

Remove multifunction steering wheel switches (4) in direction of arrow.

Installation

Make sure electrical leads are correctly routed.

Scheme 175

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

Lever out button for steering wheel heating (1) with suitable tool in direction of arrow.

Disconnect plug connection behind and remove button for steering wheel heating (1).

Scheme 176

61 31 299 Removing and installing/replacing clutch switch module

Necessary preliminary tasks

1. Remove «TRIM PANEL FOR PEDAL ASSEMBLY»(ref-381258-S24808505562010122800000) .

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 177

Installation

Clutch switch module is secured against incorrect installation.

Clutch switch module must snap audibly into place.

Scheme 178

61 31 195 Removing and installing/replacing controller

Necessary preliminary tasks

1. Remove «TRIM FOR STORAGE TRAY»(ref-381258-S22067486212010122800000)

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 179

Replacement

Carry out vehicle programming/encoding.

61 31 287 Removing and installing/replacing driving dynamics switch

Necessary preliminary tasks

1. Remove «TRIM FOR STORAGE COMPARTMENT»(ref-381258-S22067486212010122800000)

Release screws (1).

Remove driving dynamics switch (2).

Installation

Make sure driving dynamics switch (2) is correctly seated.

Scheme 180

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

Necessary preliminary tasks

1. Disconnect «battery negative lead»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting) .
2. Remove «GEARSHIFT LEVER KNOB FOR TWIN-CLUTCH GEARBOX»(/bmw/z4/e89-2009-2013/remont/automatic-trans/#gear-shift-mechanism-repair-n54__25-12-060-replacing-gearshift-lever) .
3. Remove «TRIM FOR STORAGE COMPARTMENT»(ref-381258-S22067486212010122800000) .

Release screws (1). Tightening torque 61 31 6AZ. Disconnect plug connections (2).

Scheme 181

Note. For purposes of clarity, graphic shows component removed. (Scheme 182)

Release screws (1). Feed rubber seal (2) completely out of gear selector switch (3). Release parking lock (4) at points (5) and remove gear selector switch (3).

Installation: Make sure gear selector switch (3) is exactly seated on parking lock (4). Make sure rubber seal (2) is correctly seated. Feed rubber seal (2) between center console (5) and carpet.

Scheme 182

61 31 037 Removing and installing/replacing light control unit

Necessary preliminary tasks

1. Remove «FINISHER ON LEFT INSTRUMENT PANEL TRIM»(ref-381258-S30914342192010122800000)

Release screws (1).

Remove light switch unit (2) from trim (3).

Installation

Make sure light switch unit (2) is correctly seated on trim (3).

Scheme 183

Replacement

Carry out vehicle programming/coding.

61 31 117 Removing and installing/replacing power window switch (driver's side)

Raise rocker switch (1) with special tool 00 9 317.

Feed rocker switch (1) out of door trim panel (2).

Unlock associated plug connection and disconnect.

Installation

Make sure rocker switch (1) is correctly seated.

Scheme 184

61 31 043 Removing and installing/replacing roof switch cluster

Carefully lever out roof switch center (1) with special tool 00 9 317 and lower slightly.

Scheme 185

Unlock retaining clips (1) and feed out roof switch center in direction of arrow.

Scheme 186

Disconnect plug connections (1) and remove roof switch center.

Scheme 187

Replacement

If necessary, remove BULBS .

Carry out vehicle programming/coding.

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

Necessary preliminary work

1. Remove «STEERING WHEEL»(/bmw/z4/e89-2009-2013/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-33-010-removing-and-installingreplacing) .
2. Remove «LOWER SECTION OF STEERING COLUMN TRIM»(/bmw/z4/e89-2009-2013/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-31-020-removing-and-installingreplacing) .
3. If necessary, remove switch for steering column adjustment

Note. The coil spring cassette (1) may be replaced separately, if necessary!

Scheme 188

Disconnect plug connection (1).

Scheme 189

Release screws (1).

Tightening torque 61 31 8AZ .

Remove steering-column switch cluster in direction of arrow.

Installation note

The steering column switch cluster is installed in reverse sequence.

Carry out steering angle sensor adjustment.

Scheme 190

Replacement

1. Remove volute spring cassette
2. Carry out vehicle programming/encoding NOTE: If replacement of the steering column switch cluster is initiated via Progman, the steering column switch cluster is coded indirectly via the DSC control unit If coding is cancelled, first adjust the steering angle sensor; this makes a brand-new steering-column switch cluster coding-compatible again if necessary Then code the DSC control unit again
3. Carry out steering angle sensor adjustment NOTE: If steering angle sensor adjustment is cancelled, first code the DSC control unit Then adjust the steering angle sensor again
4. Vehicles with active steering: Steering angle sensor is adjusted by means of initial operation/adjustment of active front steering If necessary, proceed in accordance with instructions

61 31 172 Removing and installing/replacing switch for electromechanical parking brake

Necessary preliminary tasks

1. «DISCONNECT NEGATIVE BATTERY LEAD»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting) (to avoid fault memory entries)
2. Remove «TRIM FOR STORAGE TRAY»(ref-381258-S22067486212010122800000)

Release screws (1).

Remove switch for electromechanical parking brake (2) from trim for storage compartment (3).

Scheme 191

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

Necessary preliminary tasks

1. Remove «OUTER COVER ON FRONT SEAT»(/bmw/z4/e89-2009-2013/remont/seats/#seats-repair__52-13-040-removing-and-installingreplacing)

Expand catches (1) of cover (2).

Unclip switch for front lumbar support (3) in direction of arrow and remove.

Scheme 192

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

Carefully lever out switch for hazard warning system/central locking (1) with special tool 00 9 341 in direction of arrow.

Remove switch for hazard warning system/central locking (1) in direction of arrow and disconnect plug connection behind.

Scheme 193

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).

If necessary, remove FOOTWELL SIDE TRIM PANEL ON A-PILLAR, LEFT .

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

Scheme 194

61 31 011 Removing and installing/replacing volute spring cassette

Necessary preliminary tasks

1. Remove «STEERING-COLUMN SWITCH CLUSTER»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-31-008-removing-and-installingreplacing)

Unlock catches (1).

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

Scheme 195

Installation

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

Scheme 196

Scheme 197

61 31 310 Replacing brake light switch

Necessary preliminary tasks

1. Remove «TRIM PANEL FOR PEDAL ASSEMBLY»(ref-381258-S24808505562010122800000) .

Note. Brake light switch (2) is situated above the brake pedal.

Disconnect plug connection (1).

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

Press catches (4) together and unclip brake light switch holder (3) from brake pedal.

Scheme 198

Installation

Depress brake pedal.

Slide brake light switch (2) as far as it will go into brake light switch holder (3).

Grip brake light switch holder (3), slowly return brake pedal to starting position and pull back to stop.

61 31 382 Replacing coolant level switch

Unlock plug connection (1) on level switch (2) and disconnect.

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

Scheme 199

61 31 118 Replacing front passenger power window switch

Carefully lever out rocker switch (1) in area (2) with special tool 00 9 323.

Feed rocker switch (1) out of door trim panel (3).

Unlock associated plug connection and disconnect.

remove rocker switch (1).

Installation

Make sure rocker switch (1) is exactly seated.

Scheme 200

61 31 492 Replacing level switch for windscreen washer system

Unlock retaining lugs (1).

Remove fluid tank for windscreen washer system (2).

Scheme 201

Unfasten plug connection (1) and disconnect.

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

Installation

Make sure level switch for windscreen washer system (2) is correctly seated.

Scheme 202

61 31 204 Replacing switch combination for seat adjustment

Necessary preliminary tasks

1. Remove «OUTER COVER»(/bmw/z4/e89-2009-2013/remont/seats/#seats-repair__52-14-040-removing-and-installingreplacing) on front seat

Disconnect plug connection (2).

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

Installation

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

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

Scheme 203

61 31 270 Replacing switch for reversing light

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

Necessary preliminary tasks

1. If necessary, remove «REAR UNDERBODY PROTECTION»(/bmw/z4/e89-2009-2013/remont/axle-shafts/#rear-axle-repair__51-47-491-removing-and-installingreplacing)

Version A

Disconnect plug connection (1).

Release switch for reversing light (2).

Tightening torque 61 31 2AZ .

Scheme 204

Version B

Disconnect plug connection (1).

Release switch for reversing light (2).

Tightening torque 61 31 2AZ .

Scheme 205

61 33 040 Removing and installing/replacing a fanfare horn

Necessary preliminary tasks

1. Remove «FRONT LEFT WHEEL ARCH COVER»(ref-381258-S19052335092010122800000)

Unlock plug connections (1) and disconnect.

Release screws (2) and remove fanfare horn (3) complete with holder.

Scheme 206

Replacement

Slacken nut (1).

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

Scheme 207

61 33 060 Removing and installing/replacing both fanfare horns

Operation is described in

1. Removing «A FANFARE HORN»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-33-040-removing-and-installingreplacing)

61 34... Removing and installing/replacing 12-V socket in the front storage compartment

Necessary preliminary tasks

REMOVE COVER FOR FRONT STORAGE COMPARTMENT

Press together tabs in direction of arrow and remove the cover (1) forwards.

Expose cable at positions (3) and (5).

Carefully unclip lighting from storage compartment (2) and socket (4).

Scheme 208

Pull the 12-V socket with special tool 61 0 250 from the storage compartment housing until the connector is below on the light ring.

Scheme 209

Unlock tabs with suitable tool in direction of arrow and release light ring (1).

Pull out 12-V socket completely, including light ring and cable.

Scheme 210

61 34... Removing and installing/replacing 12V socket in center armrest storage compartment

Necessary preliminary tasks

REMOVE CENTRE CONSOLE.

Remove 12V socket with special tool 61 0 250.

61 35 679 Initializing rain/light (solar) sensor

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

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

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

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

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

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

Scheme 211

Example

Mechatronic control unit.

Scheme 212

Scheme 213

Personal protective equipment

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

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

Scheme 214

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

Necessary preliminary tasks

1. Clamp off «BATTERY NEGATIVE LEAD»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting)
2. Remove «TRIM PANEL FOR PEDAL ASSEMBLY»(ref-381258-S24808505562010122800000) x

Unlock plug connections (1) and disconnect.

Scheme 215

Unlock control unit for Car Access System (1) at points (2).

Remove control unit for Car Access System (1) in direction of arrow.

Scheme 216

Installation

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

Scheme 217

Replacement

Carry out 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.

Scheme 218

Disconnect plug connection (3).

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

Installation note

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

If necessary, initialize RAIN/LIGHT SENSOR .

Scheme 219

Replacement

Carry out programming/encoding.

61 35 107 Removing and installing or replacing junction box electronics

Necessary preliminary tasks

1. Clamp off «BATTERY NEGATIVE LEAD»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting)
2. Remove «TRIM FOR INSTRUMENT PANEL»(ref-381258-S34209930902010122800000) , bottom right

Unfasten plug connection (1) and disconnect.

Release screw (2).

Fold down passenger compartment fuse box (3) in direction of arrow.

Scheme 220

Unlock plug connections (1) and disconnect.

Release screws (2) and pull junction box electronics (3) out of holder in direction of arrow.

Installation

Make sure junction box electronics (3) are correctly seated.

Scheme 221

Replacement

Carry out vehicle programming/coding.

Delete transport mode.

61 35 146 Removing and installing/replacing Convertible top module

Necessary preliminary tasks

1. Remove «RIGHT LOADING SILL END COVER»(ref-381258-S27881162722010122800000)

Unlock plug connections (1) and disconnect.

Pull Convertible top module (2) out of device holder (3).

Scheme 222

Replacement

Carry out vehicle programming/coding.

61 35 975 Removing and installing/replacing bumper aerial for comfort access system

Necessary preliminary tasks

1. Remove «REAR BUMPER TRIM»(ref-381258-S20276974502010122800000)

Disconnect plug connection (1).

Unlock and remove bumper aerial for comfort access system (2) from holder (3).

Installation

Make sure bumper aerial for comfort access system (2) is correctly seated in designated holder (3).

Scheme 223

61 35 080 Removing and installing/replacing control unit/module for left or right seat adjustment

Note. Move seat completely towards rear/top.

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

Disconnect all associated plug connections.

Scheme 224

Installation

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

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

Scheme 225

Replacement

Carry out vehicle programming/coding.

61 35 095 Removing and installing/replacing control unit/module for seat heating

Note. Move seat completely towards rear/top.

Disconnect plug connection (1).

Open lock (2) in direction of arrow and remove control unit/module for seat heating (3) towards bottom.

Installation

Make sure control unit/module for seat heating (3) is correctly engaged.

Scheme 226

61 35 115 Removing and installing/replacing footwell module

Necessary preliminary tasks

1. Clamp off «BATTERY NEGATIVE LEAD»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-20-900-disconnecting-and-connecting)
2. Remove «TRIM PANEL FOR PEDAL ASSEMBLY»(ref-381258-S24808505562010122800000)

Unlock plug connections (1) and disconnect.

Unclip footwell module (2) at points (3).

Carefully pull footwell module (2) out of device holder (4) in direction of arrow.

Scheme 227

Unfasten plug connection (1) and disconnect.

Remove footwell module (2).

Scheme 228

Replacement

Carry out vehicle programming/coding.

61 35 953 Removing and installing/replacing interior aerial for comfort access system (version 1)

Necessary preliminary tasks

1. Remove «TRIM FOR STORAGE COMPARTMENT»(ref-381258-S22067486212010122800000)

Disconnect plug connection (1).

Unlock and remove interior aerial for comfort access system (2) from holder (3).

Installation

Make sure interior aerial for comfort access system (2) is correctly seated in designated holder (3).

Scheme 229

61 35 954 Removing and installing/replacing interior aerial for comfort access system (version 2)

Remove rear cover (1) from center console (2) towards top.

Disconnect plug connection behind.

Unlock and remove interior aerial for comfort access system (1) from holder (2).

Installation

Make sure interior aerial for comfort access system (1) is correctly seated in designated holder (2).

Scheme 230

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

Necessary preliminary tasks

1. Remove «LUGGAGE COMPARTMENT FLOOR TRIM PANEL»(ref-381258-S02647489252010122800000)

Disconnect plug connection (1).

Unlock and remove aerial for comfort access system (2) from holder (3).

Installation

Make sure interior aerial for comfort access system (2) is correctly seated in designated holder (3).

Scheme 231

64 11 970 Replacing fogging sensor

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

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

Disconnect plug connection (1).

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

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

Installation

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

Scheme 232

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

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

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

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

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

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

Scheme 233

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

Vehicle programming and encoding

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

Programming sequence via ISTA/P

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

Programming sequence via Progman

Select menu item (1).

Select corresponding procedure from selection list.

For example

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

Scheme 234

61 61... Adjusting left or right windscreen wiper

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

Scheme 235

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.

For RHD vehicles, change the preceding sign of the scale values.

1. LHD cars, scale range 0 to - -10
2. RHD cars, scale range 0 to +10

SCALE VALUE REFERENCE CHART

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

Note. Wipe quality is improved by precise adjustment of CONTACT/APPROACH ANGLE of wiper arms. Adjustment angle can be checked with special tool 00 9 331 or 61 6 100.

Checking with setting gauge

Before checking approach angle, briefly lift windscreen wiper arms off windscreen.

Place special tool 00 9 331 next to pivot point of wiper blade on windscreen.

Check light gap, adjust wiper arm if necessary.

Scheme 236

Note. Tape off wiper arm with fabric adhesive tape to avoid damage.

Press special tools 00 9 220 in appropriate direction until correct contact/approach angle is obtained.

Scheme 237

Checking with angulometer

Remove wiper blades.

Insert windscreen wiper arm (1) in angle meter 61 6 100.

Using screw (2) and pressure plate (3), locate windscreen wiper arm (1) and position on windscreen.

Read off value in degrees, adjust wiper arm if necessary.

Scheme 238

Note. Windscreen wiper arm (1) must rest correctly on lower and side contact surfaces (4) of angle meter 61 6 100. On right-hand-drive cars, screw (2) must be located on left side of special tool 61 6 100.

Press special tools 00 9 220 in appropriate direction until correct contact/approach angle is obtained.

Scheme 239

Scheme 240

61 61 270 Removing and installing or replacing bracket for windscreen wiper system complete with motor

Necessary preliminary tasks

1. Remove «COWL PANEL COVER»(ref-381258-S09596401072010122800000)

Unfasten plug connection (1) and disconnect.

Unclip and remove clamping lever (2).

Installation

If necessary, replace clamping lever (2).

Release screws (3).

Tightening torque 61 61 1AZ .

Remove wiper bracket (4) upwards.

Scheme 241

Installation

Make sure wiper bracket (4) is exactly seated.

Installation

Before fitting the wiper arms, allow the windscreen 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.

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

Remove cover (1).

Scheme 242

Release nut (1), tightening torque 61 61 2AZ .

Scheme 243

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

Scheme 244

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 dimensions

1. Driver's side: 52±2 mm
2. Passenger side: 57±2 mm

Scheme 245

61 61 041 Replacing both windscreen wiper blades

Press retaining spring in direction of arrow. Pull windscreen wiper blade towards wiper arm and feed out.

Scheme 246

61 61 021 Replacing left or right windscreen wiper blade

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

61 67 040 Adjusting spray nozzles for headlight washer system

Note. The spray nozzles of the headlight washer 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.

Scheme 247

61 67 088 Removing and installing/replacing left or right high-pressure nozzle of headlight washer system

Operation is described in

1. Removing «LEFT HIGH-PRESSURE NOZZLE OF HEADLIGHT WASHER SYSTEM»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-67-083-removing-and-installingreplacing)

61 67 083 Removing and installing/replacing left or right high-pressure nozzle of headlight washer system

Necessary preliminary tasks

1. Remove «COVER FOR HEADLIGHT WASHER SYSTEM»(ref-381258-S09680132922010122800000)
2. Remove «FRONT BUMPER TRIM»(ref-381258-S34243602582010122800000) .

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

Pull locks (2) in direction of arrow.

Pull high-pressure nozzle of headlight washer 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 washer system (3) is correctly seated.

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

Scheme 248

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

Note. Catch any escaping washer fluid if necessary.

Unfasten plug connection (1) and disconnect.

Turn washer pump of headlight washer system (2) in direction of arrow.

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

Detach washer pump of headlight washer system (2) from fluid reservoir in upward direction.

Scheme 249

Installation

1. Replace strainer for washer pump of headlight washer system.
2. Coat sealing ring of washer pump for headlight washer system with antiseize agent.
3. Lay hose of washer pump for headlight washer system without kinks
4. Fill fluid reservoir

Scheme 250

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

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

Unfasten plug connection (1) and disconnect.

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

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

Installation

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

Ensure hose is laid without kinks.

Scheme 251

61 71 030 Removing and installing/replacing all spray nozzles of windscreen washer system

Operation is described in

1. Removing «A SPRAY NOZZLE OF WINDSCREEN WASHER SYSTEM»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-71-015-removing-and-installingreplacing)

61 71 100 Removing and installing/replacing windscreen washer pump

Note. Drain fluid reservoir for windscreen washer system.

Unfasten plug connection (1) and disconnect.

Unlock clamp (2) and detach washing water line from windscreen washer pump (3).

Press windscreen washer pump (4) in direction of arrow.

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

Scheme 252

Installation

Replace sealing ring and strainer in windscreen washer pump.

Coat sealing ring of windscreen washer pump with antiseize agent.

Fill fluid reservoir for windscreen washer system.

61 71 061 Replacing fluid reservoir for windscreen washer system

Necessary preliminary tasks

1. Remove «WINDOW WASHER PUMP»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-71-100-removing-and-installingreplacing)
2. Remove «WASHER PUMP FOR HEADLIGHT WASHER SYSTEM»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-67-010-removing-and-installingreplacing)
3. Remove «LEVEL SWITCH»(/bmw/z4/e89-2009-2013/remont/horns/#general-electrical-system-repair__61-31-492-replacing-level-switch)

Release detent lugs (1) and remove fluid reservoir (2) towards top.

Installation

Make sure fluid reservoir for windscreen washer system (2) is correctly seated in existing guides.

See also:
• 61 21 1AZ
• SAFETY REGULATIONS
• AIRBAG UNIT
• GEARSHIFT LEVER KNOB FOR TWIN-CLUTCH GEARBOX
• BULBS
• STEERING WHEEL
• LOWER SECTION OF STEERING COLUMN TRIM
• OUTER COVER ON FRONT SEAT
• OUTER COVER
• REAR UNDERBODY PROTECTION
• SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY
• BATTERY NEGATIVE LEAD
• 6113... CUTTING OFF, STRIPPING INSULATION AND CUTTING OPTICAL FIBRES TO LENGTH
• 6113... CRIMPING OPTICAL FIBRES
• BUTT CONNECTORS AND HEAT-SHRINK HOSES
• REPAIRING AIRBAG CABLES
• INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY
• SPECIAL TOOLS FOR WIRING HARNESS REPAIRS
• CUTTING CABLES TO LENGTH AND STRIP INSULATION
• 6113... CRIMPING MICRO QUADLOCK SYSTEM CONTACTS (MQS)
• 6113... CRIMPING MICRO POWER QUADLOCK CONTACTS (MPQ)
• 6113... CRIMPING STOP PARTS
• COMB CONNECTOR FOR RETROFITTING/REPAIRS
• INTELLIGENT BATTERY SENSOR IBS
• 6100... NOTES ON HANDLING WIRING HARNESSES AND CABLES
• INSTRUCTIONS FOR OPENING CONTACTS AND LOCKS
• JUNCTION BOX ELECTRONICS
• STEERING ANGLE SENSOR ADJUSTMENT
• OBSERVE NOTE ON BATTERY REPLACEMENT
• BOTH SWITCHES FROM SPORT STEERING WHEEL
• protection against electrostatic damage (ESD protection)
• STEERING-COLUMN SWITCH CLUSTER
• A FANFARE HORN
• RAIN/LIGHT SENSOR
• CONTACT/APPROACH ANGLE
• CHECK/ADJUST
• LEFT HIGH-PRESSURE NOZZLE OF HEADLIGHT WASHER SYSTEM
• A SPRAY NOZZLE OF WINDSCREEN WASHER SYSTEM
• WINDOW WASHER PUMP
• WASHER PUMP FOR HEADLIGHT WASHER SYSTEM
• LEVEL SWITCH