Repairing airbag 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)

CAUTION: Only repair those cables which show visible signs of damage. In the event of visible damage, make sure there is only one cable repair in effect after the repair work. If no visible damage can be identified, the entire cable must be replaced. When carrying out repairs to the airbag wiring harness, you must use the spare parts offered in the applicable BMW Parts Catalogue.

SAFETY REGULATIONS for handling components of airbag system.

INSTRUCTIONS for disconnecting and connecting battery.

In event of non-visible damage to wiring harness:

Disconnect plug connection on airbag module or on plug adapter. It is absolutely vital to disconnect the contacts in succession as there is a risk of mixing up (similar parts)! Cut through one cable after the other at an appropriate position, do not under any circumstances cut through both cables at the same time. Insulate cables remaining in wiring harness with insulating tape. Now disconnect the plug connection from the airbag control unit. Unpin contacts. Cut through one cable after the other at an appropriate position and insulate with insulating tape, do not under any circumstances cut through both cables at the same time. Pin the contacts of the repair cable for the airbag control unit into the control-unit connector, the allocation of the repair cables is relevant. Lay repair cable in vehicle parallel to existing airbag lead. Now pin the contacts for the airbag module or the contacts of the plug adapter, the allocation of the repair cables is relevant. Cut off excess length of repair cable in proximity (visible area) of airbag module or of plug adapter. Twist open cables. With the butt connectors and heat-shrink tubings in the applicable BMW Parts Catalogue, reconnect the cables with the same cable colors. Twist cables again, open length (twist) must not exceed 40 mm. Secure interface (heat-shrink tubing) with insulating tape to prevent cables from twisting open.

In event of visible damage:

Expose cable at damaged areas. Cut through one cable after the other at an appropriate position and insulate cables no longer required in wiring harness with insulating tape, do not under any circumstances cut through both cables at the same time. Now, depending on the work scope, unpin the contacts either on the airbag control unit or on the airbag module or plug adapter. Cut off unpinned cables. Insulate cables remaining in wiring harness with insulating tape. Now pin in contacts of repair cable, assignment of repair cables is relevant. Lay repair cable in vehicle parallel to existing airbag lead up to separation point. Cut off excess length of repair cable. Twist open cables. Connect cables with butt connectors and heat-shrink tubings in applicable BMW Parts Catalogue, assignment of repair cables is relevant. Twist cables again, open length (twist) must not exceed 40 mm. Secure interface (heat-shrink tubing) with insulating tape to prevent cables from twisting open.

Instructions for cutting off, insulating, crimping cables, installing and removing contacts:

Cutting off and INSULATING CABLES .

REPAIR a plug connection using butt connectors. Install and remove contacts.