Notes on handling wiring harnesses and cables (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)

The following applies in general:

To avoid damage, observe the following repair 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 components; 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.
For aerial lines only the bushing contact may be repaired.
RG174 Lines and the bushing contact may not be repaired.

CVBS cables

CVBS cables may not be repaired.
CVBS cables must be replaced in their entirety

HSD cables

HSD cables may not be repaired.
HSD cables must be replaced in their entirety.

Fibre-optic cables:

NOTE: Fibre-optic cables are colored differently as follows:

Green = MOST (M edia O riented S ystems T ransport) optical fibres
Yellow = ISIS (I ntelligent S afety and I ntegration S ystem) optical fibres
Orange=repair fibre-optic cables

CAUTION:

Optical fibres are permitted to show only one junction point (bridge). Replace optical fibres if necessary
Smallest permissible bending radius is 25 mm
Avoid effects of heat ≥ 85°

TREATING CABLES and optical fibres.

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 NOTES .

NOTE:

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:

Repair airbag CABLES .

Replacing wiring harnesses

Repair wiring harnesses mainly cover the full equipment of the vehicle. If certain optional equipment is not installed in the vehicle, note the following:

If necessary, secure the remaining connectors.
If necessary, seal the remaining connectors outside the vehicle interior, for example, with butyl tape in such a way that moisture ingress can be eliminated permanently.
If necessary, repin the connector of the repair wiring harness.

NOTE: Repair wiring harnesses can be equipped with an additional socket housing (30-pin, for example), which was not provided on the previous vehicle-side wiring harness . This socket housing also cannot be found in the wiring diagram.

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.