61 11... Installing the EPS repair wiring harness

NOTE: The EPS repair wiring harness fits the steering gear manufactured by the ZF and TKP company.

Necessary preliminary work:

Disconnect negative battery lead
REMOVE THE SOUND INSULATION FROM THE UPPER BULKHEAD SECTION
Remove front underbody protection
REMOVING FRONT WHEEL ARCH COVER (FRONT SECTION), RIGHT
Place the coolant expansion tank to one side:
- Loosen screws.
- If necessary unfasten plug connection.
- Do not pull off the coolant connections.

Courtesy of BMW OF NORTH AMERICA, INC.

Carefully lift the tabs (5).

Remove the sealing on the upper section of the partition wall (4).

Remove the cable (6) towards the top.

Detach the brake line (8) at the point marked by the arrow.

Release screws (7).

Remove the partition wall sealing (3).

Slacken nut (1).

Disconnect positive line (2) and place to one side.

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: The line (2) from repair wiring harness (1) will not be required. A line installed in the vehicle will be used.

Removing line (2) from the repair wiring harness (1):

Mark all the adhesive tape positions as shown (4).
Remove all cable straps.
Open cable channel (3).
Remove all the adhesive tape.
Remove line (2).

Disconnect plug connection (1).

Release wiring harness retainers (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Release wiring harness retainers (1).

Slacken nut (2).

Remove grounding cable on wiring harness (3) from ground pin.

Release cable channel (4) from front axle support.

Remove cable strap from cable channel (4).

Open cable channel (4) and remove wiring harness (3).

Courtesy of BMW OF NORTH AMERICA, INC.

Remove all cable straps in the area shown.

Remove all the adhesive tape in the area shown.

Remove line (1) from wiring harness (2).

Disconnect the positive line from wiring harness (2) at point (3). Do not damage line (1) while doing so.

Remove wiring harness (2) (both thick cables).

Wiring harness (2) is no longer needed.

Mount cable channel (4) on front axle support.

Mount grounding cable from repair wiring harness (3) on ground support point (1).

Tighten nut (1).

Tightening torque: 9 Nm.

Fasten line (2) and repair wiring harness (3) together at the places marked by the arrow using adhesive tape.

Courtesy of BMW OF NORTH AMERICA, INC.

Courtesy of BMW OF NORTH AMERICA, INC.

Courtesy of BMW OF NORTH AMERICA, INC.

Connect plug connection (2) of repair wiring harness (1).

Connect plug connection (3) of line (4).

Route repair wiring harness (1) and line (4) as shown.

Fasten line (4) and repair wiring harness (1) together at the places marked as shown, using adhesive tape.

Place repair wiring harness (1) and line (4) in cable channel (6).

Shut cable channel (6).

Position repair wiring harness (1) and line (4) such that the cable straps lie on the adhesive tape.

Fasten repair wiring harness (1) and line (4) at points (5) using cable straps on the front axle support.

Slacken nut (1).

Remove ground cable (2) and place to one side.

Courtesy of BMW OF NORTH AMERICA, INC.

Courtesy of BMW OF NORTH AMERICA, INC.

Attention!

Risk of damage!

Do not damage the lines (3) when removing the adhesive tape.

Open cable channel (1).

Remove adhesive tape from wiring harness (2).

NOTE: The bonding area is marked by the dotted line.

Courtesy of BMW OF NORTH AMERICA, INC.

Unpin pin 2 of the positive line (5) from connector (1) that is no longer required:

Lift tabs (3) carefully.

Push back sealing (4).

Open primary locking device (6) in the direction of the arrow.

Unpin pin 2 (7) of the positive line (5) using a suitable tool.

Connector (1) with positive line (2) is no longer required.

Pin positive line (5) in the connector (1) of the repair wiring harness:

Pin pin 2 (7) of the positive line (5).

Close primary locking device (6) against direction of arrow.

Push sealing (4) upwards and engage correctly on the connector (1).

Courtesy of BMW OF NORTH AMERICA, INC.

Close connector (1).

Secure repair wiring harness (2), positive line (3) and wiring harness (4) using adhesive tape at the points marked with an arrow as shown in the figure.

Wrap all the wiring harnesses (2) mentioned in the last operation beginning with (1) and ending with (3) with adhesive tape.

NOTE: The bonding area is marked by the dotted line.

Courtesy of BMW OF NORTH AMERICA, INC.

Close cable channel (1).

Secure cable channel (1) at the points marked with an arrow using cable straps.

Wrap cable channel (1) with adhesive tape as shown.

Courtesy of BMW OF NORTH AMERICA, INC.

Courtesy of BMW OF NORTH AMERICA, INC.

Secure repair wiring harness (3) and line (1) at point (2) with adhesive tape.

Wrap repair wiring harness (3) and line (1) beginning with (4) and ending with (5) with adhesive tape.

Wrap mounting elements for wiring harness (3) at the points marked with an arrow, as well.

Secure wiring harness (3) at the points marked with an arrow.

NOTE: The bonding area is marked by the dotted line.

Secure wiring harness (2) with a cable strap at point (1).

Fasten grounding cable (4) using the nut (3).

Tightening torque: 9 Nm.

NOTE: The figure of coolant expansion tank (5) can vary depending on the vehicle and the engine.

Courtesy of BMW OF NORTH AMERICA, INC.

Fasten the coolant expansion tank (5).

Close plug connection, if necessary.

Courtesy of BMW OF NORTH AMERICA, INC.

Position positive line (2) and fasten with nut (1).

Tightening torque: 15 Nm.

Install partition wall sealing (3) and fasten with screws (7).

Tightening torque: 2.5 Nm.

Attach the brake line (8) at the point marked by the arrow.

Install wiring harnesses (6).

Fit upper section of partition wall sealing (4) until tabs (5) engage correctly.

Add final details to vehicle:

Install center bulkhead upper part sound insulation
Connect battery earth lead
Install front underbody protection
Install front wheel arch cover (front section), right