Repair of airbag system wires (BMW X3 E83)

Caution: Only wires that are visibly damaged should be repaired. If there is visible damage, you need to be sure that after the repair there will be only one place where the wires need to be repaired. If no visible damage can be found, the entire wire must be replaced. When repairing the electrical wiring of the airbag system, you should use spare parts offered in the Electronic Parts Catalog (ETC).

In case of invisible damage to the wiring harness

Disconnect the connector on the airbag module or on the junction plug. The contacts must be disconnected sequentially, as there is a risk of incorrect installation. Cut the wires one by one in a suitable place (under no circumstances cut both wires together). Insulate the remaining wires in the bundle with electrical tape. After this, disconnect the connector on the airbag control unit. Remove the contacts from the connector. Cut the wires one by one in a suitable place (under no circumstances cut both wires together) and insulate with electrical tape. Insert the contacts of the repair wire of the airbag control unit into the control unit connector. The distribution of contacts in the repair wire connectors is important. Route the repair wire in the vehicle parallel to the existing airbag system wire. Then, connect the airbag module contacts or the connectors of the junction plug. The distribution of contacts in the repair wire connectors is important. Cut off excess length of repair wire in the immediate vicinity (in a prominent place) from the airbag system module or branch plug. Strip the wires. Reconnect the wires of the same color using butt connectors and cambric sleeves, as listed in the Electronic Parts Catalog (EPC). Strip the wires again; the exposed wire length (stripping) should not exceed 40 mm. Secure the cut area (cambric sleeves) with electrical tape to prevent the wires from becoming exposed.

In case of visible damage

Release the wire at the damaged area. Cut the wires one by one in a suitable place (under no circumstances cut both wires together) and insulate unnecessary wires in the bundle with electrical tape. After this, depending on the scope of work, remove the contacts from the connector of the airbag system control unit/airbag system module or from the branch plug. Cut off the wires with the contacts removed. Insulate the remaining wires in the bundle with electrical tape. After this, insert the contacts of the repair wire. The distribution of contacts in the repair wire connectors is important. Lay the repair wire in the car parallel to the existing airbag system wire up to the cut point. Cut off the excess piece of repair wire. Strip the wires. Connect the wires using butt connectors and cambric connectors found in the Electronic Parts Catalog (EPC). The pin assignment in the repair wire connectors is important. Clean the wires again, the length of the exposed wire (stripping) should not exceed 40 mm. Fix the cut area (cambricks) with an insulating tape in order to prevent the wires from being exposed.