Notes on handling wiring harnesses and cables (Cooper Convertible)
The following applies in general:
To avoid damage, observe the following instructions:
- Avoid compressive and tensile loads
- To ensure professional repairs, perform repair work only with BMW-approved or recommended special tools and spare parts
- Make sure cables are laid without kinks or abrasions
- Ensure non-contacting routing at sharp-edged body parts; use edge protection if necessary
- Secure additionally laid cables/leads with cable ties
The following additionally applies
Shielded lines:
Interference radiation and interference resistance can lead to neutral zones at contact points in the shielding. Consequently, distinctions have to be drawn between the following types:
Coaxial cable:
- Shielded coaxial cables RTK031 may only be repaired with a special crimping tool 02 02 10 (622).
- For antenna wires only the contact bushing may be repaired.
- RG174 Lines and the contact bushing may not be repaired.
CVBS cables:
- CVBS cables may not be repaired.
- CVBS cables must be replaced in their entirety.
HSD lines:
- HSD lines may not be repaired.
- HSD lines must be replaced in their entirety.
Fiber-optic cables:
- Green = MOST (M edia O riented S ystems T ransport) optical fibers
- Yellow = ISIS (I ntegrated S ervice and Information S erver) optical fiber
- Orange=repair optical fibers
Attention!
- Optical fibers are permitted to show only one separation point (bridge). Replace OPTICAL FIBERS if necessary
- Smallest permissible bending radius is 25 mm
- Avoid effects of heat ≥ 85°
Working with cables and optical fibers:
FlexRay (twisted cables):
It is possible to repair the FlexRay. In the event of damage, the cables can be joined with conventional BUTT CONNECTORS AND HEAT-SHRINK TUBING .
- FlexRay lines may only reveal one separation point (bride); replace complete line if necessary.
- If possible, maintain twisted cable after repair.
- After repairs, twist cables as close as possible to the connector/separation point.
- Twisting must be as symmetrical as possible.
Airbag lines:
See: REPAIRING AIRBAG CABLES .
Ribbon cables:
Repairing ribbon cables
Replacement of wiring harnesses:
Repair wiring harnesses mostly cover the full scope of vehicle equipment. If certain optional equipment is not installed in the vehicle, observe the following:
- Fasten any remaining plugs.
- Seal any remaining plugs outside the vehicle interior, e.g. with butyl tape, so that there is permanent protection against moisture ingress.
- If necessary, wrap the plug of the repair wiring harness.
Procedure:
The separation point between the vehicle-side wiring harness and the repair wiring harness is located in the vehicle interior (in the footwell, for example):
- Cut the additional socket housing and connect the lines to the vehicle-side wiring harness using a butt connector.
- Alternatively, a suitable pin housing can be fitted on the vehicle-side wiring harness and connected to the additional socket housing.
However, this is permitted only if the following conditions are met:
- Carpets must not protrude visibly or become deformed due to the installation of the additional plug connection.
- It must be possible to install the adjacent components (for example, trims, trim panels, etc.) correctly after installing the additional plug connection.
- All the attachment points of the adjacent components (for example, trims, trim panels, etc.) must engage correctly.
- There must be no rattling noise due to the installation of the additional plug connection.
- The additional plug connection must not damage the adjacent components/wiring harnesses, etc..
The separation point between the vehicle-side wiring harness and the repair wiring harness is located outside the vehicle interior (in the wheel arch, for example):
- Cut the additional socket housing and connect the lines to the vehicle-side wiring harness using a butt connector.
- Using the additional socket housing is not permitted with a separation point outside the vehicle interior.