2006 MINI Cooper 2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10

2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10

TROUBLESHOOTING 12 00 ... INSTRUCTIONS ON STARTING AID Do not start the engine with help of starting sprays. Preparation: Conform with the following when starting engine with starting cable.    

Ensure that jump lead wires are to appropriate cross-section size. Only use fuse-protected jump leads. Check whether the current supplying battery has 12 V voltage. If engine is started from battery of another vehicle, ensure that there is no contact between the bodies of both vehicles. CAUTION: Never touch ignition system components and current - dangerous high tension!

If the battery in the vehicle supplying power is weak, start the engine of this vehicle and let it run at idling speed. Carrying out: Always conform with the procedures to avoid injury to persons or damage to parts.      

On automatic transmission, select "P" setting, apply handbrake. Move the shift lever of vehicles with manual transmission into neutral and apply the parking brake. Ensure that the jump leads cannot get caught in rotating parts, e.g. fan. First connect positive terminals of both batteries with one jump lead (red). Use positive connection point in engine compartment for vehicles with one battery in trunk. Then attach second jump lead (black) to negative terminal of donor battery and to engine ground or body ground on vehicle to be started. CAUTION: Never connect second jump lead (black) to negative terminal of battery in vehicle to be started. This would produce explosive gas which could be ignited by sparks.

Danger Of Explosion! Microsoft Tuesday, February 16, 2010 12:05:52 12:05:46 PM

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2006 MINI Cooper 2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10

After engine of vehicle to be started has started up, first disconnect the jump lead on the negative terminal/ground connection. Then remove jump lead from positive terminals. 61 00 ... BATTERY NOTE:  

  

Important notes and instructions for handling batteries can be found in:

Battery master document. Disconnecting battery. 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY. Battery charging. Refer to 61 00 ... BATTERY CHARGING. Welding work. External jump-starting aid.12 00 ... INSTRUCTIONS ON STARTING AID.

Battery Care And Maintenance: In low-maintenance batteries, check the acid level at least once a year. If necessary, top up with distilled water up to the top marking. The increasing number of electronic control units in the car reduces the self-discharging time of the battery (even in standby mode). To maintain the battery service life and to avoid exhaustive discharging, recharge laidup vehicles every 6 weeks at the latest. The time for self-discharging depends on vehicle type and equipment specification. Battery test: The battery acid density can be used to measure the charge state. However this test produces uncertainty caused by a design-related range of variation. The acid density e.g. for a charged battery is 1.28 kg/l (in the tropical version the acid density is 1.23 kg/l). Another interference factor is the acid lamination immediately after filling with distilled water. Battery wear with partially sulfated and/or heavily contaminated plates will also lead to incorrect acid density test results. 61 00 ... BATTERY CHARGING If a normal or quick charger is used to charge the battery, the battery must be disconnected from the vehicle electrical system and removed. This prevents damage to paintwork and upholstery. Ideally, battery charging is performed with BMW-approved charging computers. IMPORTANT: In order to prevent the intelligent battery sensor from malfunctioning, the charging terminals in the engine compartment must be used without fail in vehicles from E60 and should be used if possible in other vehicles. Microsoft Tuesday, February 16, 2010 12:05:46 PM

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2006 MINI Cooper 2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10

IMPORTANT: Before charging the battery while it is installed, first carry out a closed-circuit current test. 61 20 ... BATTERY OPEN-CIRCUIT CURRENT TEST. If here the voltage is 10 V or less, one or more of the cells may be faulty or the entire battery may already be damaged. In this case, always remove the battery as escaping gases during charging could damage the interior equipment and trim. Attempt to regenerate faulty cells with low charging current. If necessary, open existing plugs on the individual cells. 61 00 ... REPAIRING AIRBAG CABLES IMPORTANT: 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 Electronic Parts Catalogue (EPC). Safety Regulations: Safety regulations for handling components of airbag system. Refer to AIR BAG SAFETY PRECAUTIONS . Instructions for disconnecting and connecting battery. Refer to 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY. Procedure For Cable Repair: In Event Of Non-Visible Damage To Wiring Harness: Disconnect plug connection on airbag module or on adapter plug. It is absolutely vital to disconnect the contacts in succession as there is a risk of them being mixed up! 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 plug connection on 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 contacts of repair cable for airbag control unit in control unit plug, assignment of repair cables is relevant. Lay repair cable in car parallel to existing airbag lead. Now pin in contacts for airbag control unit or contacts of adapter plug, assignment of repair cables is relevant. Cut off excess length of repair cable in proximity (visible area) of airbag module or of adapter plug. Twist open cables. With the connectors and shrink-fit hoses in the Electronic Parts Catalogue (EPC), reconnect the cables with the same cable colors. Twist cables again, open length (twist) must not exceed 40 mm. Secure interface (shrink-fit hoses) with insulating tape to prevent cables from twisting open. Instructions for cutting off, insulating, crimping cables, installing and removing contacts, refer to: Cutting off and insulating cables. Repairing a plug connection using connectors. Microsoft Tuesday, February 16, 2010 12:05:46 PM

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Installing and removing contacts. 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 scope of work, unpin contacts either on airbag control unit/airbag module or on adapter plug. 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 lead in car parallel to existing airbag lead up to cutting point. Cut off excess length of repair lead. Twist open cables. Connect cables with connectors and shrink-fit hoses in Electronic Parts Catalogue (EPC), assignment of repair cables is relevant. Twist cables again, open length (twist) must not exceed 40 mm. Secure interface (shrink-fit hoses) 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. Repairing a plug connection using connectors. Installing and removing contacts. 61 00 ... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY Battery Acid Is Highly Corrosive: Do not allow any battery acid to come into contact with the eyes, the skin or clothing. Therefore wear protective clothing, gloves and goggles. Do not tilt the battery, acid may emerge from the vent opening. In Event Of Contact With Acid: If acid is splashed into the eyes, rinse them immediately for several minutes with clear water. You must then consult a doctor without delay. If acid is splashed onto the skin or clothing, neutralize it immediately with a soapy solution and rinse with lots of water. Seek medical attention immediately if battery acid is accidentally swallowed. Explosion Hazard: Strictly no flames, sparks, naked light or smoking! A highly explosive mixture of electrolytic gas is created when batteries are charged. The rooms where charging is carried out must therefore always be well ventilated. Microsoft Tuesday, February 16, 2010 12:05:46 PM

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Avoid the formation of sparks when handling cables, wiring and electrical devices. Turn the ignition lock to the 0 position before disconnecting or connecting the battery. Do not place tools or any similar object on the battery (danger of short-circuiting and explosion!). 61 13 .. UNLOCKING AND DISCONNECTING DIFFERENT PLUG CONNECTIONS NOTE:

Examples of unlocking and disconnecting different plug connections.

Press lock and open clip in direction of arrow. Disconnect plug connection.

Fig. 1: Disconnecting Plug Connection Courtesy of BMW OF NORTH AMERICA, INC. Press lock and open clip in direction of arrow. Microsoft Tuesday, February 16, 2010 12:05:46 PM

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Disconnect plug connection.

Fig. 2: Identifying Direction Of Opening Lock Courtesy of BMW OF NORTH AMERICA, INC. Open clip in direction of arrow and disconnect plug connection in direction of arrow.

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Fig. 3: Identifying Direction For Disconnecting Plug Connection Courtesy of BMW OF NORTH AMERICA, INC. Press lock and disconnect plug connection in direction of arrow.

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Fig. 4: Pressing Lock And Disconnecting Plug Connection (1 Of 6) Courtesy of BMW OF NORTH AMERICA, INC. Press lock and disconnect plug connection in direction of arrow.

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Fig. 5: Pressing Lock And Disconnecting Plug Connection (2 Of 6) Courtesy of BMW OF NORTH AMERICA, INC. Press lock and disconnect plug connection in direction of arrow.

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Fig. 6: Pressing Lock And Disconnecting Plug Connection (3 Of 6) Courtesy of BMW OF NORTH AMERICA, INC. Press lock and disconnect plug connection in direction of arrow.

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Fig. 7: Pressing Lock And Disconnecting Plug Connection (4 Of 6) Courtesy of BMW OF NORTH AMERICA, INC. Press lock and disconnect plug connection in direction of arrow.

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Fig. 8: Pressing Lock And Disconnecting Plug Connection (5 Of 6) Courtesy of BMW OF NORTH AMERICA, INC. Press lock and disconnect plug connection in direction of arrow.

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Fig. 9: Pressing Lock And Disconnecting Plug Connection (6 Of 6) Courtesy of BMW OF NORTH AMERICA, INC.

AUXILIARY CABLE 61 13 .. UNLOCKING AND DISCONNECTING DIFFERENT PLUG CONNECTIONS Operation is identical to: 61 13 .. UNLOCKING AND DISCONNECTING DIFFERENT PLUG CONNECTIONS.

PLUG CONNECTION, TERMINALS, FUSE BOX 61 00 ... REPAIRING AIRBAG CABLES Operation is identical to: 61 00 ... REPAIRING AIRBAG CABLES. 61 13 SPECIAL TOOLS FOR WIRING HARNESS REPAIRS Microsoft Tuesday, February 16, 2010 12:05:46 PM

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NOTE:

For Special Tool identification, see GENERAL ELECTRICAL SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required:          

61 1 150 61 1 190 61 4 320 61 8 084 61 9 020 61 9 029 61 9 041 61 9 042 61 9 043 61 9 044

Repair ranges I, II, III for vehicle electrical system I. Order No.: 81 24 9 408 080 II. Order No.: 81 24 9 408 300 III. Order No.: 81 24 9 408 400 NOTE:

Operating instructions for the special tools contained in these repair ranges, refer to manufacture's operating instructions.

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Fig. 10: Identifying Wiring Harness Repairing Special Tool (1 Of 5) Courtesy of BMW OF NORTH AMERICA, INC. Repair range IV for vehicle electrical system, special tool 61 9 020: Contents:  

Special tool 61 9 041 (hand pliers). Special tool 61 9 042 (matrix).

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 

Special tool 61 9 043 (wire stripper). Special tool 61 9 044 (matrix).

Fig. 11: Identifying Wiring Harness Repairing Special Tool (2 Of 5) Courtesy of BMW OF NORTH AMERICA, INC. NOTE:

Operating instructions for the special tools contained in the this repair range, refer to manufacture's operating instructions.

Special tool 61 9 043 (wire stripper with wire cutter) for cutting and stripping wires. Handling: Cutting to length and stripping insulating from cables.

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Fig. 12: Identifying Wiring Harness Repairing Special Tool (3 Of 5) Courtesy of BMW OF NORTH AMERICA, INC. Special tool 61 9 041 (hand pliers) with special tool 61 9 042 (matrix) for crimping connectors and contact tubes for fan connectors up to a wire cross-section of 2.5 mm2 and for pushing on contact tubes for fan connectors. Handling: Crimping stop parts (contacts). Fan connector for retrofitting/repairs.

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Fig. 13: Identifying Wiring Harness Repairing Special Tool (4 Of 5) Courtesy of BMW OF NORTH AMERICA, INC. Special tool 61 9 041 (hand pliers) with special tool 61 9 044 (matrix) for crimping cable guide and strain relief device on antenna elbow plug. Handling: Antenna elbow plug on radio receiver.

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Fig. 14: Identifying Wiring Harness Repairing Special Tool (5 Of 5) Courtesy of BMW OF NORTH AMERICA, INC. Special tool 61 1 150 (release and pressing-out tool) for:    

Releasing round plug housings. Releasing relay carriers. Pressing out contacts. Removing indicator lights.

Handling: Opening plug housings and removing contacts of different plug systems. Refer to 61 13 ... OPENING PLUG HOUSINGS AND REMOVING CONTACTS OF DIFFERENT PLUG SYSTEMS.

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Fig. 15: Identifying Special Tool Kit (1 Of 3) Courtesy of BMW OF NORTH AMERICA, INC. Repair kit for ignition cables and for crimping fan connector receptacles 4 mm2 . Handling: Crimping stop parts (contacts).

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Fig. 16: Identifying Special Tool Kit (2 Of 3) Courtesy of BMW OF NORTH AMERICA, INC. Special tool 61 4 320 (crimping set with pliers) for: 

 

Cutting to length and stripping insulation from optical fibers. Refer to 61 13 ... CUTTING OFF, STRIPPING INSULATION AND CUTTING OPTICAL FIBRES TO LENGTH. Crimping optical fibers. Refer to 61 13 ... CRIMPING OPTICAL FIBRES. Crimping MPQ contacts. Refer to 61 13 ... CRIMPING MICRO POWER QUADLOCK CONTACTS (MPQ).

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

Crimping MQS contacts. Refer to 61 13 ... CRIMPING MICRO QUADLOCK SYSTEM CONTACTS (MQS).

Fig. 17: Identifying Special Tool Kit (3 Of 3) Courtesy of BMW OF NORTH AMERICA, INC. Special tool 61 1 190 pliers for insulation displacement connector for repairing ribbon cables. Handling: Repairing ribbon cables.

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Fig. 18: Identifying Special Tool For Repairing Ribbon Cable Courtesy of BMW OF NORTH AMERICA, INC. 61 13 .. UNLOCKING AND DISCONNECTING DIFFERENT PLUG CONNECTIONS Operation is identical to: 61 13 .. UNLOCKING AND DISCONNECTING DIFFERENT PLUG CONNECTIONS. 61 13 ... BASE OF TAB CONNECTOR HOUSINGS Unlock hook (1) with special tool 61 1 360 and slide plug housing downwards out of base.

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Fig. 19: Locating Hook On Plug Housing Courtesy of BMW OF NORTH AMERICA, INC. 61 13 ... CRIMPING MICRO POWER QUADLOCK CONTACTS (MPQ) NOTE:

For Special Tool identification, see GENERAL ELECTRICAL SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required: 

61 4 320

To crimp MPQ contacts, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 325 (2) from crimping set 61 4 320. NOTE:

Pliers (1) open automatically as far as they will go when handles are pressed together.

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Fig. 20: Identifying Special Tool Plier And Crimping Head Courtesy of BMW OF NORTH AMERICA, INC. Open pliers (1). NOTE:

Place contact (2) with utmost care in designated nest (observe cable crosssection) in crimping head (3). Make sure it is exactly positioned.

Place MPQ contact (2) in crimping head (3). Close pliers (1) one notch.

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Fig. 21: Placing MPQ Contact In Crimping Head Courtesy of BMW OF NORTH AMERICA, INC. NOTE:

Follow procedure for cutting and stripping insulation from cables.

Insert stripped cable (2). Close pliers (1) fully. Open pliers (1) and remove cable (2). NOTE:

Check contact for correct crimping.

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Fig. 22: Removing Cable Courtesy of BMW OF NORTH AMERICA, INC. 61 13 ... CRIMPING MICRO QUADLOCK SYSTEM CONTACTS (MQS) NOTE:

For Special Tool identification, see GENERAL ELECTRICAL SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required: 

61 4 320

To crimp MQS contacts, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 324 (2) from crimping set 61 4 320. NOTE:

Pliers (1) open automatically as far as they will go when handles are pressed together.

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Fig. 23: Identifying Special Tool Plier And Crimping Head Courtesy of BMW OF NORTH AMERICA, INC. Open pliers (1). Fold up contact carrier (2). Insert MQS contact (3) in contact carrier (2). Fold back contact carrier (2).

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Fig. 24: Inserting MQS Contact In Contact Carrier Courtesy of BMW OF NORTH AMERICA, INC. NOTE:

Follow procedure for cutting and stripping insulation from cables.

Close pliers (1) one notch. Insert stripped cable (2). Close pliers (1) fully.

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Fig. 25: Inserting Stripped Cable Courtesy of BMW OF NORTH AMERICA, INC. Open pliers (1). Open contact carrier (2) gently and carefully remove MQS contact. NOTE:

Check contact for correct crimping.

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Fig. 26: View Of MQS Contact Courtesy of BMW OF NORTH AMERICA, INC. 61 13 ... CRIMPING ANNULAR CONTACTS CrimpacII crimping pliers from repair kit 1 are used to crimp annular contacts.

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Fig. 27: Identifying Crimping Plier Courtesy of BMW OF NORTH AMERICA, INC. Open crimping pliers (1). NOTE:

Place contact (2) in designated nest (observe wire cross-section) with particular care. Make sure it is exactly positioned.

Insert annular contact (2) in crimping pliers (1). Close crimping pliers (1) gently and keep closed.

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Fig. 28: Identifying Crimping Pliers Contact Courtesy of BMW OF NORTH AMERICA, INC. NOTE:

Follow procedure for cutting and stripping insulation from cables.

Feed stripped cable (1) into annular contact (2) completely. Close crimping pliers (3) fully. Open crimping pliers (3) and remove cable (2). NOTE:

Check contact for correct crimping.

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Fig. 29: Checking Contact For Correct Crimping Courtesy of BMW OF NORTH AMERICA, INC. 61 13 ... CRIMPING OPTICAL FIBRES NOTE:

For Special Tool identification, see GENERAL ELECTRICAL SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required: 

61 4 320

To crimp optical fibres, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 323 (2) from crimping set 61 4 320. NOTE:

Pliers (1) open automatically as far as they will go when handles are pressed together.

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Fig. 30: Identifying Special Tool Plier And Crimping Head Courtesy of BMW OF NORTH AMERICA, INC. Move contact guide by means of stop lever (1) into corresponding position (pin contact or jack).

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Fig. 31: Locating Stop Lever Courtesy of BMW OF NORTH AMERICA, INC. Open pliers (2). Place pin contact or jack (1) in crimping head and secure with locking lever (3).

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Fig. 32: Identifying Locking Lever Courtesy of BMW OF NORTH AMERICA, INC. NOTE:

Follow procedure for cutting and stripping insulation from optical fibres. Refer to 61 13 ... CUTTING OFF, STRIPPING INSULATION AND CUTTING OPTICAL FIBRES TO LENGTH.

Insert stripped optical fibre (1) as far as it will go into pin contact or jack (2). Close pliers (3) fully. Open pliers (3) and locking lever (4). Remove optical fibre (1).

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Fig. 33: Removing Optical Fibre Courtesy of BMW OF NORTH AMERICA, INC. IMPORTANT: Make sure optical fibre is correctly seated in jack. Right (A) End of optical fibre (1) must be flush with tip of pin contact (2). Wrong (B) End of optical fibre (1) is not flush with tip of pin contact (2).

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Fig. 34: Identifying End Of Optical Fibre Courtesy of BMW OF NORTH AMERICA, INC. 61 13 ... CUTTING OFF, STRIPPING INSULATION AND CUTTING OPTICAL FIBRES TO LENGTH NOTE:

For Special Tool identification, see GENERAL ELECTRICAL SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required: 

61 4 320

To cut off, strip insulation and cut optical fibres to length, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 322 (2) from crimping set 61 4 320. NOTE:

Pliers (1) open automatically as far as they will go when handles are pressed

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together.

Fig. 35: Identifying Special Tool Plier And Crimping Head Courtesy of BMW OF NORTH AMERICA, INC. Cutting Optical Fibre: Open pliers (1). Place optical fibre (2) in cutting device (3). Close pliers (1) and remove optical fibre (2).

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Fig. 36: Cutting Optical Fibre Courtesy of BMW OF NORTH AMERICA, INC. Stripping Insulation From Optical Fibre: Open pliers (1). Open lever (2) in direction of arrow.

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Fig. 37: Stripping Insulation From Optical Fibre Courtesy of BMW OF NORTH AMERICA, INC. Slide optical fibre (1) into stripping device (2) until flush at point (3). Close pliers (4) fully. Close clamping lever (5) in direction of arrow. Open pliers (4) by one tooth notch. Open clamping lever (5) against direction of arrow again and remove optical fibre (1). NOTE:

A stripping replacement blade set is available under number 61 4 327.

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Fig. 38: Removing Optical Fibre Courtesy of BMW OF NORTH AMERICA, INC. Cutting Optical Fibre To Length: IMPORTANT: The cutting blade must be replaced prior to each cutting of the optical fibre. Pull pin (1) in direction of arrow. Fold up blade retaining link (2) in direction of arrow.

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Fig. 39: Identifying Blade Retaining Link Courtesy of BMW OF NORTH AMERICA, INC. WARNING: Risk of injury when changing the blade.

Remove blade (1) and replace. Installation: Make sure blade (1) is correctly seated on locating points (2).

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Fig. 40: Removing/Installing Blade Courtesy of BMW OF NORTH AMERICA, INC. Open pliers (3). Slide optical fibre (1) into cutting device (2) until insulation of optical fibre (1) butts against clamping device. Close pliers (3) fully and keep closed. Remove optical fibre (1).

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Fig. 41: Removing Optical Fibre Courtesy of BMW OF NORTH AMERICA, INC. 61 13 ... OPENING PLUG HOUSINGS AND REMOVING CONTACTS OF DIFFERENT PLUG SYSTEMS Abbreviations And What They Mean: ABBREVIATIONS AND WHAT THEY MEAN MDK Miniature double flat spring contact 3plus JPT ELA Junior Power Timer flat spring contacts with strand sealing DFK ELA Double flat spring contacts with strand sealing Elo Electronic contacts with and without strand sealing Manufacturer: Siemens Elo Power Electronic contacts for heavy loads with and without strand sealing Manufacturer: Siemens Micro Quadlock System electronic contacts with and without strand sealing Manufacturer: MQS AMP Microsoft Tuesday, February 16, 2010 12:05:47 PM

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MPQ D 1.5 / 2.5

Micro Power Quadlock electronic contacts for heavy loads with and without strand sealing Manufacturer: AMP Round contacts of 1.5 mm or 2.5 mm diameter

Ultrasonic-Welded Connectors: Ultrasonic-welded connectors (1) can be identified by the welds (2) on their longitudinal side. The contacts of these connectors cannot be replaced. Replace plug completely. NOTE:

Special tools referred to in the repair instructions below are contained in the following special tool kits:

Release and press-out tool 61 1 150 Repair Instructions For Opening Plug Housings And Removing Contacts Of Different Plug Systems Plug system D 1.5/D 2.5:        

Circular plugs, 7-, 8-pin, System D 2.5. Circular plugs, 13-pin, System D 2.5. Circular plugs, 20-pin, System D 2.5. Circular plugs, 4-, 7-, 10-, 12-, 25-pin, System D 1.5/D 2.5. In-line plugs, 15-pin, System D 2.5. In-line plugs, 8-, 12-pin, System D 2.5. In-line plugs, 30-pin, System D 2.5. In-line plugs, 20-pin, System D 2.5.

Plug system JPT/MDK/DFK:   

In-line plugs, 2-pin, System JPT ELA. In-line plugs, 2-pin, System MDK 3plus 2.8. In-line plugs, 4-pin, System DFK ELA.

Plug system Elo/Elo-Power:   

In-line plugs, 4-, 10-pin, System Elo. In-line plugs, 6- to 50-pin, System Elo. In-line plugs, 3-, 6-pin, System Elo-Power 2.8.

Plug system MQS/MPQ: 

In-line plugs, 6-, 8-pin, System MQS.

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       

In-line plugs, 2-pin, System MPQ 2.8. Control unit plugs, 25-, 35-, 55-, 83-, 88-pin. In-line plugs, 24-pin, Hybrid System MQS/MPQ. Socket housing 42-, 43-pin, Hybrid System MQS / MPQ. Socket housings, 2x21-, 2x27-pin, Hybrid System MQS/MPQ, Elo/Elo-Power. In-line plugs, 30-pin, Hybrid System MQS/MPQ. Socket housings, 5-, 8-pin, System MQS/MPQ. Socket housing (radio plug), Hybrid System MQS/MPQ.

61 13 ... RELAY CARRIER Place special tool 61 1 153 on relay carrier (1) and carefully pull in direction of arrow until retaining lugs (2) on relay carrier are raised.

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Fig. 42: Removing Relay Carrier Courtesy of BMW OF NORTH AMERICA, INC. Pull relay carrier (2) in direction of arrow into first catch (3).

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Fig. 43: Locating First Catch Courtesy of BMW OF NORTH AMERICA, INC. Press down arrester hook (4) of appropriate contact and pull out cable with contact. Press out double flat spring contact with special tool 61 1 136 or 61 1 137 (ejector).

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Fig. 44: Removing Double Flat Spring Contact Courtesy of BMW OF NORTH AMERICA, INC. 61 13 ... RETAINING BRACKET Pull relevant fuse out of fuse block (1). NOTE:

Mark positions when removing fuses.

Pull locking slide (2) out of fuse block (1) as far as it will go.

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Fig. 45: Removing Locking Slide From Fuse Block Courtesy of BMW OF NORTH AMERICA, INC. With special tool 61 1 136 or 61 1 137 (ejector), press back arrester hook (3) of appropriate contact and pull out cable.

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Fig. 46: Pressing Arrester Hook Courtesy of BMW OF NORTH AMERICA, INC. 61 13 ... SOCKET HOUSING (RADIO PLUG), HYBRID SYSTEM MQS/MPQ Manufactured By AMP: The following contact types without strand sealing can be fitted in the plug housings:   

MQS (Micro Quadlock System). MPQ, width 2.8 mm (Micro Power Quadlock). MPQ, width 5.2 mm (Micro Power Quadlock).

Removing MPQ Contacts From Radio Plug: Press lock (1) in direction of arrow. Detach secondary lock (2) from radio plug. Microsoft Tuesday, February 16, 2010 12:05:47 PM

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Fig. 47: Detaching Secondary Lock Courtesy of BMW OF NORTH AMERICA, INC. Feed special tool 61 1 135 past side of contact. Press special tool 61 1 135 in direction of arrow. Pull wire (1) with socket contact out of radio plug (2).

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Fig. 48: Removing Wire With Socket Contact Out Of Radio Plug Courtesy of BMW OF NORTH AMERICA, INC. Removing MQS Contacts From Contact Carrier: Press lock (1) in direction of arrow and pull housing (2) out of radio plug.

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Fig. 49: Removing MQS Contacts From Contact Carrier Courtesy of BMW OF NORTH AMERICA, INC. Press lock (1) in direction of arrow. Pull contact carrier (2) out of housing (3). NOTE:

When the contact carrier is pulled out, the secondary locks of the socket contacts are raised.

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Fig. 50: Pulling Contact Carrier Out Of Housing Courtesy of BMW OF NORTH AMERICA, INC. Hold down retaining hook (1) of socket contact in opening of contact carrier with a small screwdriver. Pull wire with socket contact in direction of arrow as far as secondary lock (2). NOTE:

The illustration shows an 8-pin socket housing where removal of the contacts is identical.

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Fig. 51: Removing Socket Housing Contacts Courtesy of BMW OF NORTH AMERICA, INC. Hold down arrester hook in secondary lock (1) again. Pull wire with socket contact (2) out of contact carrier (3).

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Fig. 52: Pulling Wire With Socket Contact Out Of Contact Carrier Courtesy of BMW OF NORTH AMERICA, INC. Removing MPQ contacts from contact carrier: Remove contact carrier (1) with MQS contacts from radio plug. Raise lock (2) on radio plug. Pull contact carrier (3) out of radio plug.

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Fig. 53: Removing MPQ Contacts From Contact Carrier Courtesy of BMW OF NORTH AMERICA, INC. Press lock (1) in direction of arrow. Pull secondary lock (2) in direction of arrow completely out of contact carrier (3).

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Fig. 54: Removing Secondary Lock Courtesy of BMW OF NORTH AMERICA, INC. Press special tool 61 1 135 on inside of contact into contact carrier (2). Pull wire with socket contact (1) out of contact carrier (2).

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Fig. 55: Removing Wire With Socket Contact Out Of Contact Carrier Courtesy of BMW OF NORTH AMERICA, INC. 61 13 051 REMOVING AND INSTALLING/REPLACING FUSE BOX IN ENGINE COMPARTMENT Remove battery container. Refer to 61 21 100 REMOVING AND INSTALLING/REPLACING BATTERY CONTAINER. Release retaining clips (1) and remove fuse box cover (2).

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Fig. 56: Removing Fuse Box Cover Courtesy of BMW OF NORTH AMERICA, INC. Detach plug connector (1). Remove screws (2). Tightening torque, refer to 61 13 1AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUE - COOPER (1.6L) R50/W10 . Remove screw (3). Tightening torque, refer to 61 13 4AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUE - COOPER (1.6L) R50/W10 .

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Fig. 57: Detaching Plug Connector Courtesy of BMW OF NORTH AMERICA, INC. Disconnect plug connectors on underside of fuse box (1). Installation: Write down color and position of plug connectors before removing. Replacement only: Remove cover (2). Remove fuses and relays.

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Fig. 58: Removing Fuses And Relays Courtesy of BMW OF NORTH AMERICA, INC. 61 13 056 REMOVING AND INSTALLING/REPLACING PASSENGER COMPARTMENT FUSEBOX Disconnect battery. Refer to 12 00 DISCONNECTING AND CONNECTING BATTERY . Remove front left entrance cover strip. Refer to 51 47 000 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT ENTRANCE COVER STRIP (INSIDE) . Remove nuts (1). Tightening torque, refer to 61 13 5AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUE - COOPER (1.6L) R50/W10 . Remove connector mounting plate (2).

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Fig. 59: Removing Connector Mounting Plate Courtesy of BMW OF NORTH AMERICA, INC. Remove connectors from rear of fusebox (1). Install hint: Note colors and position of connectors prior to removal.

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Fig. 60: Removing Fuses And Relays Courtesy of BMW OF NORTH AMERICA, INC. Replacement only: Remove fuses and relays.

BATTERY 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY Operation is identical to 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY . 12 00 ... INSTRUCTIONS ON STARTING AID Operation is identical to: 12 00 ... INSTRUCTIONS ON STARTING AID. 61 00 ... BATTERY Operation is identical to:61 00 ... BATTERY. 61 00 ... BATTERY CHARGING Microsoft Tuesday, February 16, 2010 12:05:47 PM

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Operation is identical to: 61 00 ... BATTERY CHARGING. 61 00 ... REPAIRING AIRBAG CABLES Operation is identical to: 61 00 ... REPAIRING AIRBAG CABLES. 61 00 ... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY Operation is identical to: 61 00 ... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY. 61 20 ... THRESHOLD VALUES FOR BATTERY INSPECTION OF ALL BATTERY (TELEPHONE EXCEPT FOR TELEPHONE BATTERY) Safety instructions for handling vehicle battery. Refer to 61 00 ... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY. Test Step 1 - Before Charging The Battery: BATTERY CHARGING TEST STEP 1 Charge state, see 1) . Refer to 61 20 ... THRESHOLD VALUES FOR BATTERY INSPECTION OF ALL BATTERY (TELEPHONE EXCEPT FOR TELEPHONE BATTERY). Not testable

Starting capability, see 2) . Refer to 61 20 ... THRESHOLD VALUES FOR BATTERY INSPECTION OF ALL BATTERY (TELEPHONE EXCEPT FOR TELEPHONE BATTERY).

Test result Charge

less than 50 %, see 2) . Refer to 61 20 ... THRESHOLD VALUES FOR BATTERY INSPECTION OF ALL BATTERY (TELEPHONE EXCEPT FOR TELEPHONE BATTERY). more than 50 %

Charge

less than 75 %

Charge

more than 75 %, see 3) . Refer to 61 20 ... more than 50 %

more than 80 %

THRESHOLD VALUES FOR BATTERY INSPECTION OF ALL BATTERY (TELEPHONE EXCEPT FOR TELEPHONE BATTERY). more than 75 %

Charge

O.K.

Test step 2 - After Charging The Battery: BATTERY CHARGING TEST STEP 2 Charge condition, see 1) . Refer to 61 20 ... THRESHOLD VALUES FOR BATTERY INSPECTION OF ALL BATTERY (TELEPHONE EXCEPT FOR

Starting capability, see 2) . Refer to 61 20 ... THRESHOLD VALUES FOR BATTERY INSPECTION OF ALL BATTERY (TELEPHONE EXCEPT FOR

Test result

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TELEPHONE BATTERY). Not testable less than 50 % more than 50 %

TELEPHONE BATTERY). less than 75 % more than 75 %

Defective Charge Charge

1. Charge condition and starting power must always be evaluated together. 2. When test charging for more than 5 hours, use charger Gossen CG 32 or Siemens / Gossen VB 801. 3. Fully charge until charge state is more than 80 %. NOTE:

If battery was checked on the positive terminal in the engine compartment, repeat check directly on battery for sake of safety.

61 20 ... BATTERY OPEN-CIRCUIT CURRENT TEST NOTE:

Observe safety instructions for handling vehicle battery. Refer to 61 00 ... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY. Observe Service Information Adapter for open-circuit current measurement.

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Fig. 61: View Of Diagnosis And Information System Courtesy of BMW OF NORTH AMERICA, INC. The open-circuit current test is performed using the Diagnosis and Information System (DIS). Microsoft Tuesday, February 16, 2010 12:05:47 PM

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BATTERY/VAPOR SEPARATOR 61 21 010 REMOVING AND INSTALLING BATTERY WARNING: Follow safety instructions for handling vehicle battery. Refer to 61 00 ... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY. This text deals with removing the battery from the engine compartment. Removing the battery from the luggage compartment is performed in the same way. Remove rubber seal (1). Press clips in direction of arrow and remove cover.

Fig. 62: Removing Battery Cover Seal Courtesy of BMW OF NORTH AMERICA, INC. Microsoft Tuesday, February 16, 2010 12:05:47 PM

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IMPORTANT: Disconnect battery negative lead first, followed by battery positive lead (risk of short circuit). Detach vent hose (1). Release screw (2), tightening torque, refer to 61 21 1AZ in GENERAL ELECTRICAL SYSTEM TIGHTENING TORQUE - COOPER (1.6L) R50/W10 . Detach battery negative lead. Release screw (3), tightening torque, refer to 61 21 1AZ in GENERAL ELECTRICAL SYSTEM TIGHTENING TORQUE - COOPER (1.6L) R50/W10 . Detach battery positive lead. Release screws (4), tightening torque, refer to 61 21 2AZ in GENERAL ELECTRICAL SYSTEM TIGHTENING TORQUE - COOPER (1.6L) R50/W10 . Remove battery retaining bracket. Lift out battery. Installation: Connect battery in reverse sequence. Connect battery positive lead first, followed by negative lead. Make sure both battery leads run at an angle of 90° to the battery container because they are routed through openings in the battery container cover.

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Fig. 63: Locating Battery Vent Hose Courtesy of BMW OF NORTH AMERICA, INC. Installation: Initialize both power windows. Refer to 67 62 ... NOTES ON INITIALIZING POWER WINDOW UNIT (FRONT) . 61 21 100 REMOVING AND INSTALLING/REPLACING BATTERY CONTAINER Necessary Preliminary Tasks: 

 

Remove suction filter housing. Refer to13 71 000 REMOVING AND INSTALLING INTAKE FILTER HOUSING . Remove battery. Refer to 61 21 010 REMOVING AND INSTALLING BATTERY. Disconnect plug connector from EMS/DME control unit. Refer to 12 14 550 REPLACING CONTROL UNIT (DME) .

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Release screws (1) of battery container, tightening torque, refer to 61 21 3AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUE - COOPER (1.6L) R50/W10 . Remove inner fasteners (2) of battery container. Release wiring harness retaining clips (3) in base of battery container.

Fig. 64: Removing Inner Fasteners Of Battery Container Courtesy of BMW OF NORTH AMERICA, INC.

SWITCH 61 31 006 REMOVING AND INSTALLING (REPLACING) FIXTURE FOR STEERING COLUMN STALK WARNING: Move wheels into straight-ahead position and do not alter this position during the repair work. With steering wheel removed, do not under any circumstances turn/twist fixture for steering column stalk! Necessary Preliminary Tasks:  

Remove steering wheel. Refer to STEERING WHEEL . Remove lower section of steering column trim. Refer to LOWER SECTION OF STEERING COLUMN TRIM .

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

Remove top section of steering column casing. Refer to UPPER SECTION OF STEERING COLUMN TRIM . WARNING: Secure volute spring cassette (1) against rotating with adhesive tape (2).

If unauthorized rotation of volute spring cassette (1) cannot be ruled out, it is essential to return volute spring cassette (1) to center position!   

Turn volute spring counterclockwise as far as it will go. Turn volute spring clockwise as far as it will go. Turn volute spring back to center position and secure so that centering pin (3) is at bottom position.

Fig. 65: Identifying Volute Spring Cassette Courtesy of BMW OF NORTH AMERICA, INC. Microsoft Tuesday, February 16, 2010 12:05:47 PM

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Unlock plug connections (2) and disconnect. Release screws (1). Remove fixture for steering column switch (3) in direction of arrow.

Fig. 66: Locating Plug Connection For Steering Column Switch Courtesy of BMW OF NORTH AMERICA, INC. Replacement: 





Remove volute spring cassette. Refer to 61 31 011 REMOVING AND INSTALLING/REPLACING VOLUTE SPRING CASSETTE. Remove turn indicator/headlight dipping switch. Refer to 61 31 016 REMOVING AND INSTALLING/REPLACING TURN INDICATOR/HEADLIGHT DIPPING SWITCH. Remove windscreen wiper switch. Refer to 61 31 040 REMOVING AND INSTALLING/REPLACING SWITCH FOR WINDSCREEN WIPERS.

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61 31 011 REMOVING AND INSTALLING/REPLACING VOLUTE SPRING CASSETTE Necessary Preliminary Tasks: 

Remove fixture for steering column stalk. Refer to 61 31 006 REMOVING AND INSTALLING (REPLACING) FIXTURE FOR STEERING COLUMN STALK.

Expand catches (1) and remove volute spring cassette (2) from fixture for steering column switch (3).

Fig. 67: Replacing Volute Spring Cassette Courtesy of BMW OF NORTH AMERICA, INC. Replacement: Break off turning lock (1) of new volute spring cassette (2). WARNING: If the steering wheel is not reinstalled straight away, the new volute spring cassette (2) must be secured against turning with adhesive tape! Microsoft Tuesday, February 16, 2010 12:05:47 PM

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Refer to 61 31 006 REMOVING AND INSTALLING (REPLACING) FIXTURE FOR STEERING COLUMN STALK.

Fig. 68: Identifying Turning Lock Of Volute Spring Cassette Courtesy of BMW OF NORTH AMERICA, INC. 61 31 016 REMOVING AND INSTALLING/REPLACING TURN INDICATOR/HEADLIGHT DIPPING SWITCH Necessary Preliminary Tasks: 



Remove lower section of steering column trim. Refer to LOWER SECTION OF STEERING COLUMN TRIM . Remove top section of steering column casing. Refer to UPPER SECTION OF STEERING COLUMN TRIM .

Release screw (1). Microsoft Tuesday, February 16, 2010 12:05:47 PM

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Unfasten plug connection (2) and disconnect. Remove turn indicator/headlight dipping switch in direction of arrow.

Fig. 69: View Of Turn Indicator/Headlight Dipping Switch Courtesy of BMW OF NORTH AMERICA, INC. 61 31 020 REMOVING AND INSTALLING/REPLACING IGNITION STARTER SWITCH Necessary Preliminary Tasks: 

Disconnect battery negative lead. Refer to 12 00 DISCONNECTING AND CONNECTING BATTERY .

Release screws (1). Withdraw ignition starter switch. Microsoft Tuesday, February 16, 2010 12:05:47 PM

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Disconnect plug connection (2) and remove ignition starter switch.

Fig. 70: Locating Ignition Starter Switch Retaining Screws Courtesy of BMW OF NORTH AMERICA, INC. Installation: Check alignment of ignition starter switch to steering wheel lock. Check alignment of turn indicator lever to steering wheel. Secure screws with paint. 61 31 040 REMOVING AND INSTALLING/REPLACING SWITCH FOR WINDSCREEN WIPERS This operation is identical to: Removing and installing/replacing turn indicator/headlight dipping switch. Refer to 61 31 016 REMOVING Microsoft Tuesday, February 16, 2010 12:05:47 PM

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AND INSTALLING/REPLACING TURN INDICATOR/HEADLIGHT DIPPING SWITCH. 61 31 059 REMOVING AND INSTALLING/REPLACING SWITCH BLOCK IN INSTRUMENT PANEL Remove cover strips for front center console. Refer to 51 16 198 REMOVING/INSTALLING OR REPLACING TRIM BETWEEN FRONT CENTER CONSOLE AND INSTRUMENT PANEL . Remove screws (1) and pull switch block towards front to release rear retaining clips.

Fig. 71: Identifying Switch Block Retaining Screws Courtesy of BMW OF NORTH AMERICA, INC. Detach plug connector (1) from switch block.

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Fig. 72: Removing Plug Connector From Switch Block Courtesy of BMW OF NORTH AMERICA, INC. IMPORTANT: If the car has telephone provisions (optional extra), the plug connector is the same as that of the switch block in the instrument panel. Make sure the correct plug connector is reconnected. 61 31 072 REMOVING AND INSTALLING/REPLACING HEADLIGHT VERTICAL AIM CONTROL SWITCH IMPORTANT: Do not use excessive force in the following work steps. Lever out switch for headlight vertical aim control (1).

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Fig. 73: View Of Headlight Vertical Aim Control Switch Courtesy of BMW OF NORTH AMERICA, INC. Detach plug connector (2). 61 31 089 REMOVING AND INSTALLING/REPLACING SWITCH FOR TIRE PRESSURE MONITOR (TPM) Release retaining clips for sleeve of parking brake lever (the left side is shown here, mirror image for the right side) and partially remove the sleeve to expose the rear side of the TPM switch.

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Fig. 74: Identifying Retaining Clips For Sleeve Of Parking Brake Lever Courtesy of BMW OF NORTH AMERICA, INC. Press TPM switch forwards to release it from rear center console. Detach plug connector (1) from TPM switch.

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Fig. 75: Removing Plug Connector From TPM Switch Courtesy of BMW OF NORTH AMERICA, INC. 61 31 090 REMOVING AND INSTALLING / REPLACING SWITCH FOR LEFT OR RIGHT SEAT HEATING Up To 12/2001: Remove rear center console. Refer to 51 16 217 REPLACING REAR CENTER CONSOLE . Remove seat heating switch. From 12/2001: CAUTION: Do not use excessive force for following operation:

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Release switch unit (1) from front center console (in direction shown).

Fig. 76: Removing Switch Unit From Front Centre Console Courtesy of BMW OF NORTH AMERICA, INC. Disconnect connectors (1) and remove switch unit. Install Hint: Ensure all metal clips (2) are located correctly.

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Fig. 77: Locating Switch Unit Connectors Courtesy of BMW OF NORTH AMERICA, INC. 61 31 175 REMOVING/INSTALLING SUNROOF SWITCH Release switch from sunroof finisher.

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Fig. 78: View Of Switch In Sunroof Finisher Courtesy of BMW OF NORTH AMERICA, INC. Remove multiplug.

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Fig. 79: Identifying Sunroof Switch Multiplug Courtesy of BMW OF NORTH AMERICA, INC. 61 31 185 REPLACING PETROL/GASOLINE PUMP EMERGENCY SWITCH Necessary Preliminary Tasks: 

Disconnect battery negative lead. Refer to 12 00 DISCONNECTING AND CONNECTING BATTERY .

Unfasten plug connection (1) and disconnect. Release screws (2) and remove petrol/gasoline pump emergency switch.

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Fig. 80: Disconnecting Plug Connection From Petrol/Gasoline Pump Emergency Switch Courtesy of BMW OF NORTH AMERICA, INC. 61 31 222 REMOVING AND INSTALLING/REPLACING FANFARE HORN SWITCH Necessary Preliminary Tasks: 

Remove airbag unit. Refer to DRIVER-SIDE AIR BAG MODULE .

IMPORTANT: Make sure cables are correctly laid in steering wheel and cannot be trapped during assembly. Detach plug connection (1) from contact ring. Multifunction steering wheel only: Detach plug connection (2) from contact ring. Microsoft Tuesday, February 16, 2010 12:05:48 PM

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Fig. 81: View Of Plug Connection In Contact Ring Courtesy of BMW OF NORTH AMERICA, INC. Release screws (1). Carefully insert screwdriver into slot (2) in order to release locking tongue of rear switch housing (3) from front switch housing (4).

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Fig. 82: Identifying Locking Tongue Of Rear Switch Housing Courtesy of BMW OF NORTH AMERICA, INC. Disconnect wiring harness (1) from steering wheel. Disconnect plug connection (2) and remove right switch.

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Fig. 83: Removing Wiring Harness From Steering Wheel Courtesy of BMW OF NORTH AMERICA, INC. Multifunction steering wheel only: Release wiring harness (1) from clip. Disconnect plug connection (2) and remove left switch.

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Fig. 84: Locating Wiring Harness In Clip Courtesy of BMW OF NORTH AMERICA, INC. 61 31 227 REPLACING LEFT AND RIGHT SWITCHES ON SPORT STEERING WHEEL Necessary Preliminary Tasks: 

Remove airbag unit. Refer to DRIVER-SIDE AIR BAG MODULE .

Release screws (1). Unclip switches on sport steering wheel (2) in direction of arrow. Disconnect associated plug connections and remove switches from steering wheel (2).

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Fig. 85: View Of Switches On Sport Steering Wheel Courtesy of BMW OF NORTH AMERICA, INC. Installation: Make sure connecting cable (3) is correctly routed. 61 31 241 REMOVING AND INSTALLING/REPLACING ENGINE HOOD/BONNET CONTACT SWITCH Detach plug connector (1). Release switch on underside and remove in direction of arrow.

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Fig. 86: Removing Engine Hood/Bonnet Contact Switch Courtesy of BMW OF NORTH AMERICA, INC. 61 31 255 REMOVING SWITCH FOR ELECTRICALLY ADJUSTABLE DOOR MIRROR IMPORTANT: Do not use excessive force in the following work steps. Lever out mirror adjustment switch (1).

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Fig. 87: Identifying Mirror Adjustment Switch Courtesy of BMW OF NORTH AMERICA, INC. Detach plug connector (1) and remove mirror adjustment switch. Installation: Make sure all metal clips (2) are correctly seated.

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Fig. 88: Replacing Mirror Adjustment Switch Courtesy of BMW OF NORTH AMERICA, INC. 61 31 270 REMOVING/REPLACING REVERSE LAMP SWITCH Remove air filter box. Refer to 13 71 000 REMOVING AND INSTALLING INTAKE FILTER HOUSING . Remove connector. Remove reverse lamp switch (1). Tightening torque, refer to 61 31 1AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUE - COOPER (1.6L) R50/W10 .

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Fig. 89: Identifying Reverse Lamp Switch Courtesy of BMW OF NORTH AMERICA, INC. 61 31 310 REPLACING BRAKE-LIGHT SWITCH NOTE:

Brake light switch (2) is situated above the brake pedal.

Disconnect plug connection (1). Pull brake light switch (2) in direction of arrow out of brake light switch holder (4). Press catches (4) together and unclip brake light switch holder (3) from brake pedal. Installation: Depress brake pedal. Slide brake light switch (2) as far as it will go into brake light switch holder (3). Microsoft Tuesday, February 16, 2010 12:05:48 PM

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Grip brake light switch holder (3), slowly return brake pedal to starting position and pull back to stop.

Fig. 90: Locating Brake Light Switch Courtesy of BMW OF NORTH AMERICA, INC. 61 31 348 REPLACING MICROSWITCH FOR UNLOCKING REAR LID Necessary Preliminary Tasks: 

Remove strip handle (rear lid). Refer to 51 13 402 REMOVING AND INSTALLING/REPLACING STRIP HANDLE (REAR LID) .

Detach clip (1) in direction of arrow. Installation: Make sure clip (1) is correctly seated. Remove switch for unlocking rear lid (2) in direction of arrow from fixtures (3). Microsoft Tuesday, February 16, 2010 12:05:48 PM

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Cut switch cable (2) to size and strip insulation. Fit new microswitch for unlocking rear lid (2).

Fig. 91: Identifying Rear Lid Lock Microswitch Courtesy of BMW OF NORTH AMERICA, INC.

HORN 61 33 000 REPLACING HORN (ANTI-THEFT ALARM SYSTEM) Release nuts (1), tightening torque, refer to 61 35 2AZ in GENERAL ELECTRICAL SYSTEM TIGHTENING TORQUE - COOPER (1.6L) R50/W10 .

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Fig. 92: Identifying Horn Retaining Screws Courtesy of BMW OF NORTH AMERICA, INC. Disconnect plug connection (1).

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Fig. 93: Locating Plug Connection On Horn Courtesy of BMW OF NORTH AMERICA, INC. Release nut (1), tightening torque, refer to 61 35 3AZ in GENERAL ELECTRICAL SYSTEM TIGHTENING TORQUE - COOPER (1.6L) R50/W10 . Remove horn (2) from holder.

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Fig. 94: View Of Horn In Holder Courtesy of BMW OF NORTH AMERICA, INC.

ECUS MODULES 61 35 ... NOTE ON REPLACING CODABLE/PROGRAMMABLE CONTROL UNITS Replacement: Carry out coding/programming. Observe following IDC specifications:  

Programming. Coding.

61 35 ... NOTES ON ESD PROTECTION (ELECTRO STATIC DISCHARGE) Microsoft Tuesday, February 16, 2010 12:05:48 PM

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NOTE:

For Special Tool identification, see ENGINE ELECTRICAL SYSTEM - SPECIAL TOOLS .

Special Tools Required: 

12 7 060

NOTE:

Electrical components which are particularly sensitive to electrostatic discharge (electronic control units, sensors, etc.) are marked with the ESD warning symbol.

E -Electro S -Static D -Discharge Statically charged persons can discharge by touching electrical components. NOTE:

Humans can only detect a discharge starting from a level of approx. 3000 V. The danger threshold for electrical components already starts from a level of approx. 100 V.

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Fig. 95: View Of Static Discharge To Programming Unit Courtesy of BMW OF NORTH AMERICA, INC. Example: Mechatronic control unit.

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Fig. 96: View Of Mechatronic Control Unit Courtesy of BMW OF NORTH AMERICA, INC.

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Fig. 97: Identifying Precautions For Handling DIS Unit Courtesy of BMW OF NORTH AMERICA, INC. IMPORTANT: Do Not Touch Pins Or Multi-Pin Connectors Directly! Touch electrical components by their housings only. IMPORTANT: To prevent electrical components from being damaged or destroyed by electrostatic discharge, it is absolutely essential to comply with the following instructions: 





When replacing electrical components, leave the replacement components in their original packaging until immediately before they are to be installed. If necessary, always return a removed component in its original packaging (always pack the component away immediately). Read and comply with user information on using the associated ESD special tool 12 7 060.

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Fig. 98: Identifying Programming Unit (DIS) Courtesy of BMW OF NORTH AMERICA, INC. 61 35 175 REMOVING AND INSTALLING/REPLACING RAIN SENSOR Necessary Preliminary Tasks: 

Unclip and remove mirror base covers.

Pull out locks (1) in direction of arrow and remove rain sensor (2). Disconnect plug connection (3) and remove rain sensor (2). Installation: Do not damage optical element covered by rain sensor (2). If necessary, initialize rain sensor (2). Refer to 61 35 680 INITIALIZING RAIN SENSOR. Microsoft Tuesday, February 16, 2010 12:05:48 PM

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Fig. 99: Removing Rain Sensor Courtesy of BMW OF NORTH AMERICA, INC. 61 35 510 REMOVING AND INSTALLING OR REPLACING ELECTRONIC BODY MODULE (ZKE) Necessary Preliminary Tasks:  

Disconnect battery. Refer to 12 00 DISCONNECTING AND CONNECTING BATTERY . Remove right entrance cover strip. Refer to 51 47 000 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT ENTRANCE COVER STRIP (INSIDE) .

Release nuts (1) and remove ZKE.

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Fig. 100: Removing Right Entrance Cover Strip Courtesy of BMW OF NORTH AMERICA, INC. Disconnect multiple connector (1).

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Fig. 101: Disconnecting Multiple Connector Courtesy of BMW OF NORTH AMERICA, INC. Replacement: Carry out programming/coding. Refer to DIAGNOSIS PROGRAMMING/CODING. Version up to 09/03: It is necessary to adjust the headlights when ZKE (1) BC1 with ribbed metal housing is replaced by ZKE (2) BCRD with plastic housing. Refer to 63 10 004 ADJUSTING HEADLIGHTS . Build date from 09/03 or replacement of same ZKE: No adjustment of headlights necessary.

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Fig. 102: Adjusting Headlights Necessary Courtesy of BMW OF NORTH AMERICA, INC. 61 35 680 INITIALIZING RAIN SENSOR NOTE:

Initialization is necessary:  

NOTE:

 

After replacing windscreen. When installing a used rain sensor. Connect BMW diagnosis system. Initializing rain sensor.

61 35 790 REMOVING AND INSTALLING/REPLACING CONTROL UNIT FOR HEADLIGHT VERTICAL AIM ADJUSTMENT Microsoft Tuesday, February 16, 2010 12:05:48 PM

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Necessary Preliminary Tasks: 



Disconnect battery negative lead. Refer to 12 00 DISCONNECTING AND CONNECTING BATTERY . Remove storage compartment in instrument panel (passenger side). Refer to 51 16 390 REMOVING AND INSTALLING/REPLACING INSTRUMENT PANEL TRIM STORAGE TRAY (PASSENGER SIDE) .

Release nuts (1), tightening torque, refer to 61 35 4AZ in GENERAL ELECTRICAL SYSTEM TIGHTENING TORQUE - COOPER (1.6L) R50/W10 . Disconnect plug connection (2) and remove control unit for headlight vertical aim adjustment.

Fig. 103: Removing Control Unit For Headlight Vertical Aim Adjustment Courtesy of BMW OF NORTH AMERICA, INC. Replacement: Microsoft Tuesday, February 16, 2010 12:05:48 PM

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Carry out programming/coding. Refer to DIAGNOSIS PROGRAMMING/CODING. 61 35 900 REMOVING AND INSTALLING/REPLACING RING ANTENNA OF ELECTRONIC IMMOBILIZER NOTE:

For Special Tool identification, see GENERAL ELECTRICAL SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required: 

61 3 300

Remove rubber cover for ignition switch. Attach special tool 61 3 300 so that flat end (A) points to ring antenna of electronic immobilizer. Unclip ring antenna of electronic immobilizer to passenger side. Disconnect associated plug connection and remove immobilizer ring antenna.

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Fig. 104: Disconnecting Associated Plug Connection Courtesy of BMW OF NORTH AMERICA, INC. 61 35 910 REMOVING AND INSTALLING/REPLACING CONTROL UNIT OF ELECTRONIC IMMOBILIZER Necessary Preliminary Tasks: 



Disconnect battery negative lead. Refer to 12 00 DISCONNECTING AND CONNECTING BATTERY . Remove storage compartment in instrument panel (driver's side). Refer to 51 16 392 REMOVING AND INSTALLING/REPLACING STORAGE COMPARTMENT IN INSTRUMENT PANEL TRIM (DRIVER'S SIDE) .

Release nuts (1), tightening torque, refer to 61 35 1AZ in GENERAL ELECTRICAL SYSTEM TIGHTENING TORQUE - COOPER (1.6L) R50/W10 . Disconnect plug connection (2) and remove immobilizer control unit. Microsoft Tuesday, February 16, 2010 12:05:48 PM

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UK Vehicles Only: The control unit of the electronic immobilizer is protected by a metal bracket. Nuts (1) are special tamperproof nuts.

Fig. 105: Removing Immobilizer Control Unit Courtesy of BMW OF NORTH AMERICA, INC. Replacement: Carry out programming/coding. Refer to DIAGNOSIS PROGRAMMING/CODING. DIAGNOSIS PROGRAMMING/CODING Using the current TIS CD:  

Document type: Select SI Diagnosis Coding. Index number 11: Select Programming Information to display the table of contents.

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

Select the current IDC for the appropriate vehicle.

RELAYS 61 13 ... RELAY CARRIER Operation is identical to: 61 13 ... RELAY CARRIER.

WINDSCREEN WIPERS 61 61 010 CHECKING/ADJUSTING CONTACT ANGLE OF WINDSCREEN WIPER ARMS ON WINDSCREEN NOTE:

For Special Tool identification, see MAINTENANCE AND GENERAL INFORMATION - SPECIAL - COOPER (1.6L) R50/W10 and GENERAL ELECTRICAL SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required:   

00 9 220 00 9 230 61 6 100

NOTE:

The wipe quality is improved by precise adjustment of the wiper arm contact angle. Adjustment angle can be checked with special tool 00 9 230 or 61 6 100.

Checking with setting gauge: Before checking approach angle, briefly lift windscreen wiper arms off windscreen. Place special tool 00 9 230 next to pivot point of wiper blade on windscreen. Check light gap, adjust wiper arm if necessary.

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Fig. 106: Installing Special Tool Courtesy of BMW OF NORTH AMERICA, INC. NOTE:

Tape off wiper arm with fabric adhesive tape to avoid damage.

Press special tools 00 9 220 in appropriate direction until correct contact/approach angle is obtained.

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Fig. 107: Aligning Wiper Blade Using Bending Tool Courtesy of BMW OF NORTH AMERICA, INC. Checking with angulometer: Remove wiper blades. Insert windscreen wiper arm (1) in angulometer 61 6 100. Using screw (2) and pressure plate (3), locate windscreen wiper arm (1) and position on windscreen. Read off value in degrees, adjust wiper arm if necessary. NOTE:

Windscreen wiper arm (1) must rest correctly on lower and side contact surfaces (4) of angulometer 61 6 100. On right-hand-drive cars, screw (2) must be located on left side of special tool 61 6 100.

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Fig. 108: View Of Angulometer Courtesy of BMW OF NORTH AMERICA, INC. Press special tools 00 9 220 in appropriate direction until correct contact/approach angle is obtained.

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Fig. 109: Aligning Wiper Arm Courtesy of BMW OF NORTH AMERICA, INC. 61 61 041 REPLACING BOTH WINDSCREEN WIPER BLADES Press retaining spring in direction of arrow. Pull wiper blade in direction of wiper arm and remove.

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Fig. 110: Replacing Windscreen Wiper Blades Courtesy of BMW OF NORTH AMERICA, INC. 61 61 081 REMOVING AND INSTALLING/REPLACING WINDSCREEN WIPER ARM NOTE:

For Special Tool identification, see GENERAL ELECTRICAL SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required: 

61 2 100

Pull off protective cap.

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Fig. 111: Removing Protective Cap Courtesy of BMW OF NORTH AMERICA, INC. Retaining lugs (1) and fasteners (2) of protective cap (3) must not be damaged.

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Fig. 112: Identifying Retaining Lugs, Fasteners And Protective Cap Courtesy of BMW OF NORTH AMERICA, INC. Unscrew and remove nut. Installation: Tightening torque, refer to 61 61 1AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUE - COOPER (1.6L) R50/W10 .

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Fig. 113: Locating Nut For Tightening Courtesy of BMW OF NORTH AMERICA, INC. IMPORTANT: Do not bend wiper arm when removing (risk of breakage). Remove wiper arm with special tool 61 2 100.

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Fig. 114: Removing Wiper Arm With Special Tool Courtesy of BMW OF NORTH AMERICA, INC. Set wiper arm to rest position and then tighten down wiper arm nut. 1. 59 mm. 2. 60 mm. Tightening torque, refer to 61 61 1AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUE - COOPER (1.6L) R50/W10 .

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Fig. 115: Identifying Wiper Arm Position Courtesy of BMW OF NORTH AMERICA, INC. 61 61 270 REMOVING AND INSTALLING COMPLETE WIPER CONSOLE Remove cowl panel cover. Release nut (1). Installation: Make sure holder is correctly positioned in relation to grommet. Remove screws (2). Installation: (All Fastenings): Tightening torque, refer to 61 61 2AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUE - COOPER (1.6L) R50/W10 . Disconnect plug connector from engine and remove wipe mechanism/engine.

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Fig. 116: Removing Wipe Mechanism/Engine Courtesy of BMW OF NORTH AMERICA, INC.

REAR WINDOW WIPER 61 62 020 REMOVING AND INSTALLING/REPLACING REAR WIPER BLADE Raise wiper arm from rear windscreen. Press wiper blade in direction of arrow to release blade from wiper arm.

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Fig. 117: Releasing Blade From Wiper Arm Courtesy of BMW OF NORTH AMERICA, INC. 61 62 030 REPLACING (REMOVING AND INSTALLING) WIPER ARM FOR REAR WINDOW WIPER (FROM 07/2004) NOTE:

For Special Tool identification, see GENERAL ELECTRICAL SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required: 

61 6 210

Open protective cap (1). Slacken nut (3) two turns. Tightening torque, refer to 61 62 1AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUE Microsoft Tuesday, February 16, 2010 12:05:48 PM

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- COOPER (1.6L) R50/W10 . IMPORTANT: To avoid damaging the spray nozzle, it is necessary in addition to the special tool to use a suitable socket for detaching the rear window wiper from the wiper motor. Press off wiper arm (2) with special tool 61 6 210 and suitable socket (4). Unscrew nut (3). Remove wiper arm (2).

Fig. 118: Removing Wiper Arm Courtesy of BMW OF NORTH AMERICA, INC. Installation: Rear window wiper must be in rest position. Microsoft Tuesday, February 16, 2010 12:05:48 PM

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Adjust distance (1) between wiper arm and rear window edge. 1. 44 mm. Replacement: Remove and install rear window wiper blade. Refer to 61 62 020 REMOVING AND INSTALLING/REPLACING REAR WIPER BLADE.

Fig. 119: Removing Rear Window Wiper Blade Courtesy of BMW OF NORTH AMERICA, INC. 61 62 030 REPLACING (REMOVING AND INSTALLING) WIPER ARM FOR REAR WINDOW WIPER (UP TO 07/2004) NOTE:

For Special Tool identification, see GENERAL ELECTRICAL SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

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Special Tools Required: 

61 6 210

Open protective cap with integrated spray nozzle (1) to expose nut. Release nut on wiper arm. Tightening torque, refer to 61 62 1AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUE - COOPER (1.6L) R50/W10 . Press off wiper arm (2) with special tool 61 6 210.

Fig. 120: Removing Wiper Arm With Special Tool Courtesy of BMW OF NORTH AMERICA, INC. Engagement tongues (1) and inlet of spray nozzle (2) in protective cap (3) must not be damaged. Microsoft Tuesday, February 16, 2010 12:05:48 PM

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Fig. 121: Identifying Spray Nozzle Courtesy of BMW OF NORTH AMERICA, INC. Installation: Rear window wiper must be in rest position. Adjust distance (1) between wiper arm and rear window edge. 1. 44 mm. Replacement: Remove and install rear window wiper blade. Refer to 61 62 020 REMOVING AND INSTALLING/REPLACING REAR WIPER BLADE.

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Fig. 122: Removing/Installing Rear Window Wiper Blade Courtesy of BMW OF NORTH AMERICA, INC. 61 62 060 REMOVING AND INSTALLING/REPLACING REAR WINDOW WIPER MOTOR Remove rear wiper arm. Refer to 61 62 030 REPLACING (REMOVING AND INSTALLING) WIPER ARM FOR REAR WINDOW WIPER (UP TO 07/2004). Remove inside tailgate trim. Refer to 51 49 005 REMOVING AND INSTALLING/REPLACING TRIM FOR LOWER REAR LID . Disconnect connectors (1) and remove screws (2). Remove rear window wiper motor. Microsoft Tuesday, February 16, 2010 12:05:48 PM

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Install hint: Tightening torque, refer to 61 62 2AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUE - COOPER (1.6L) R50/W10 .

Fig. 123: Removing Rear Window Wiper Motor Courtesy of BMW OF NORTH AMERICA, INC. NOTE:

Inspect wiper motor spindle grommet for any signs of damage.

61 62 100 ADJUSTING JET NOZZLE FOR REAR WINDOW WASHER UNIT Adjustment measurements:

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Fig. 124: Identifying Measurements For Jet Nozzle Courtesy of BMW OF NORTH AMERICA, INC. NOTE:

The spray must meet the contact point (3). CAUTION: Do not insert any pointed objects in nozzle (risk of damage).

Mark contact point with adhesive tape. Adjust jet nozzle (1) with screwdriver in slot.

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Fig. 125: Locating Jet Nozzle Courtesy of BMW OF NORTH AMERICA, INC.

HEADLIGHT WASHER SYSTEM 61 67 000 REPLACING FLUID RESERVOIR FOR HEADLIGHT CLEANING SYSTEM The fluid reservoir for the headlight cleaning system is located on the left side of the car. This operation is identical to 61 71 061 REPLACING FLUID RESERVOIR FOR WINDSCREEN WASHER SYSTEM. 61 67 010 REMOVING AND INSTALLING/REPLACING WASHER PUMP OF HEADLIGHT CLEANING SYSTEM NOTE:

Drain fluid reservoir for headlight cleaning system.

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Necessary Preliminary Tasks: 

Remove front left wheel arch trim. Refer to 51 71 040 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH LINER .

Detach hose (1) from holder on fluid reservoir for headlight cleaning system. Remove retaining ring (2) from fluid reservoir for headlight cleaning system. Installation: Modify retaining ring (2). Unfasten plug connection (3) and disconnect. Withdraw washer pump for headlight cleaning system from fluid reservoir for headlight cleaning system.

Fig. 126: Removing Plug Connection Microsoft Tuesday, February 16, 2010 12:05:48 PM

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Courtesy of BMW OF NORTH AMERICA, INC. Open lock and detach hose from washer pump for headlight cleaning system. Installation: Replacing sealing ring/strainer on washer pump for headlight cleaning system. Coat sealing ring of washer pump for headlight cleaning system with antiseize agent. Make sure hose is laid without kinks.

Fig. 127: Replacing Sealing Ring/Strainer On Washer Pump Courtesy of BMW OF NORTH AMERICA, INC. 61 67 045 REMOVING AND INSTALLING/REPLACING SPRAY NOZZLES FOR LEFT OR RIGHT HEADLIGHT CLEANING SYSTEM Microsoft Tuesday, February 16, 2010 12:05:48 PM

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NOTE:

For Special Tool identification, see MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required: 

00 9 341

Pull nozzle carrier (1) out of headlight cleaning system (2) and secure with special tool 00 9 341.

Fig. 128: View Of Nozzle Carrier Courtesy of BMW OF NORTH AMERICA, INC. Carefully lift off chrome cover (1) from trim (2) with screwdriver (3).

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Fig. 129: Identifying Chrome Cover Courtesy of BMW OF NORTH AMERICA, INC. Carefully press retaining lugs (1) together with pointed pliers (2) and remove trim (3).

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Fig. 130: Locating Retaining Lugs On Trim Courtesy of BMW OF NORTH AMERICA, INC. Remove special tool 00 9 341. Release hose connection piece (1) by pressing release tongue (2) on headlight washer system (4). Release fastening tongue (3), slide headlight cleaning system (4) in direction of arrow and remove.

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Fig. 131: View Of Hose Connection Piece Courtesy of BMW OF NORTH AMERICA, INC. Installation: Following parts of headlight cleaning system (1) must not be damaged or missing: 1. Fastening tongue. 2. Retaining lugs.

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Fig. 132: Identifying Headlight Cleaning System Components Courtesy of BMW OF NORTH AMERICA, INC. Retaining lugs (1) and (2) of chrome cover (3) must not be damaged or missing. Installation: Position trim (4) under individual retaining lug (1) and clip in the other two retaining lugs (2).

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Fig. 133: Identifying Retaining Lugs Of Chrome Cover Courtesy of BMW OF NORTH AMERICA, INC.

WINDOW WASHER SYSTEM 61 71 004 ADJUSTING WINDSCREEN WASHER NOZZLES NOTE:

For Special Tool identification, see MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required: 

00 9 200

Dual nozzle system: Mark contact points with adhesive tape or felt-tip marker and actuate windscreen washer system. The jet sprays Microsoft Tuesday, February 16, 2010 12:05:48 PM

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must hit the middle of these areas. Adjustment values in mm:

Fig. 134: Identifying Contact Points Of Jet Sprays Courtesy of BMW OF NORTH AMERICA, INC. Mark contact point with adhesive tape. Adjust washer nozzles with special tool 00 9 200.

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Fig. 135: Adjusting Washer Nozzles With Special Tool Courtesy of BMW OF NORTH AMERICA, INC. 61 71 015 REMOVING AND INSTALLING/REPLACING A SPRAY NOZZLE IN WINDSCREEN WASHER SYSTEM Necessary Preliminary Tasks: 

Detach hood/bonnet noise insulation in rear area. Refer to 51 48 001 REMOVING AND INSTALLING/REPLACING ENGINE HOOD/BONNET SOUND INSULATION .

Remove hose (1). If necessary, disconnect associated plug connection. Press retainer (2) together and remove spray nozzle for windscreen washer system.

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Fig. 136: Identifying Spray Nozzle Retainer Courtesy of BMW OF NORTH AMERICA, INC. 61 71 061 REPLACING FLUID RESERVOIR FOR WINDSCREEN WASHER SYSTEM Necessary Preliminary Tasks: 





Remove front right auxiliary turn indicator light. Refer to 63 13 200 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT AUXILIARY TURN SIGNAL LAMP . Remove front right wheel arch trim. Refer to 51 71 040 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH LINER . Remove windscreen washer pump. Refer to 61 71 100 REMOVING AND INSTALLING/REPLACING WINDSCREEN WASHER PUMP.

Release screw (1), tightening torque, refer to 61 61 3AZ in GENERAL ELECTRICAL SYSTEM TIGHTENING TORQUE - COOPER (1.6L) R50/W10 . Microsoft Tuesday, February 16, 2010 12:05:48 PM

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Fig. 137: Locating Screw For Removal Courtesy of BMW OF NORTH AMERICA, INC. Release screw and nut (1), tightening torque, refer to 61 61 3AZ in GENERAL ELECTRICAL SYSTEM TIGHTENING TORQUE - COOPER (1.6L) R50/W10 . Pull underside of fluid reservoir for windscreen washer system forwards in direction of arrow. Detach hoses/lines (2) from clips from fluid reservoir for windscreen washer system. Release wiring harness clip (3). Remove fluid reservoir for windscreen washer system. Installation: Make sure hoses/lines (2) are laid without kinks. Microsoft Tuesday, February 16, 2010 12:05:49 PM

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Fig. 138: Installing Hose/Lines Courtesy of BMW OF NORTH AMERICA, INC. 61 71 100 REMOVING AND INSTALLING/REPLACING WINDSCREEN WASHER PUMP NOTE:

Drain fluid reservoir for windscreen washer system.

Turn steering wheel to full right lock. Necessary Preliminary Tasks: 

Detach front right wheel arch trim in rear area. Refer to 51 71 040 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH LINER .

Release windscreen washer pump from clip (1). Pull windscreen washer pump out of fluid reservoir for windscreen washer unit. Microsoft Tuesday, February 16, 2010 12:05:49 PM

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Fig. 139: Releasing Windscreen Washer Pump From Clip Courtesy of BMW OF NORTH AMERICA, INC. Unfasten plug connection (1) and disconnect. Detach hoses (2) and remove windscreen washer pump. Installation: Replace sealing ring/strainer of windscreen washer pump. Coat sealing ring of windscreen washer pump with antiseize agent. Make sure hoses (2) are laid without kinks.

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Fig. 140: Installing Hose/Lines Courtesy of BMW OF NORTH AMERICA, INC.

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