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SI B 63 03 06 Lights

February 2007 Technical Service

This Service Information bulletin supersedes S.I. B63 03 06 dated January 2007. designates changes to this revision
SUBJECT

Poor Connection at Rear Lamp Connector


MODEL

E46 (3 Series) sedan from 9/01 to 3/05 production


SITUATION

Some customers may complain that one of the rear lights is inoperative.
CAUSE

Minor corrosion at the 8-pin rear lamp connector creates high resistance causing damage to the connector housing.
CORRECTION

Repair the damaged wire(s) and replace damaged connector housing. Install additional ground wires to both left and right rear lamps.
PROCEDURE

1. In the event of a customer complaint, check the affected rear lamp connector for damage. If no problem can be found then continue with normal diagnosis. If damage is seen follow the procedure below. In order to install an additional ground wire, a special ground wire with splice must be prepared. 2. Prepare wire #1: Cut a piece of brown wire to a length of 120 mm. Strip the ends of the wire. Crimp blade contact SLK 2.8 P/N 12 52 1 433 217 on one end of wire. Crimp the flat contact for comb-type connectors P/N 61 13 1 387 144 on the other end of the wire. Put wire #1 to one side. 3. Prepare wire #2: Cut a piece of brown wire to a length of 120 mm. Strip the ends of the wire. Crimp the flat plug-in sleeve to one end of the wire P/N 07 11 9 975 531. Crimp the flat contact for comb-type connectors on the other end of the wire P/N 61 13 1 387 144. Put wire #2 to one side.

4. Remove the brown ground wire from the 8-pin rear lamp connector (pin 2 of X338 or Pin 3 of X339) and cut off the existing terminal. 5. Strip the end of the wire and install flat contact (1) P/N 61 13 1 387 144. (wire #3)

6. Cut off 3 pins from the comb-type connector contact strip (1) P/N 61 13 1 387 150. 7. Connect the three ground wires to the 3-pin contact strip (1) to create a splice.

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8. Insert the 3-pin contact strip with wires into the comb-type connector housing (1) P/N 61 13 1 393 718 and engage.

9. Fit the flat plug-in sleeve P/N 07 11 9 975 531 from wire #2 (1) onto the existing lug of the lamp holder (2).

10. Repeat steps 2-9 to prepare and install a ground splice for the remaining rear lamp.

11. For the non damaged rear lamp connector, install the blade contact of wire #1 in accordance with the pin assignment in the 8-pin socket housing (1). Pin 2 of X338 for left rear lamp or pin 3 of X339 for right rear lamp. 12. For damaged rear lamp connector housings perform the following procedure.

13. Note the wire color(s) and pin location(s) of the wires. Refer to the vehicle ETM if necessary. 14. Remove all of the wires from the 8-pin connector housing and inspect for damage at the terminal end. Any damaged wire(s) or corroded terminals must be repaired (See steps 15-17). 15. Cut the damaged wire(s) approximately 50 mm (Dimension A) from the terminal end and strip the end of the wire(s).

16. Cut the prefabricated repair wire P/N 12 52 0 007 171 to a length of approximately 50 mm (Dimension A) and strip the end of the wire.

17. Crimp the repair wire to the vehicle harness using the crimp connector (1) P/N 61 13 8 353 747 and install heat shrink tubing (2) P/N 61 13 1 379 833. Make sure to slide the heat shrink tubing onto the wire before crimping.

18. Reinstall the wires in the new connector housing P/N 12 52 7 519 956 together with ground wire #1. Use the pin locations noted down in step 13 above.

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PARTS INFORMATION

Note: The parts listed below are for one side only. If the repair is needed for both rear lamps then you will need to double the quantity of parts. Part Number 12 52 7 519 956 12 52 0 007 171 Description 8-pin connector housing blade contact SLK 2.8 with a wire length of 500 mm, 1.0 mm 12 52 1 433 217 blade contact SLK 2.8 without wire for a cable cross section of 1.5 mm 61 13 8 353 747 61 13 1 379 833 61 13 1 393 718 61 13 1 387 150 61 13 1 387 144 07 11 9 975 531 Source Locally
TOOLS NEEDED

Quantity 1 6

crimp connector 1.0 mm shrink sleeve comb-type connector (housing) 3-pin comb-type connector (contact strip) flat contact for comb-type connectors flat plug-in sleeve 4.8-2.5 Brown wire, 1.5 mm, length approximately 120 mm Description Crimping pliers Wire strippers Pliers for comb-type connectors Die-plate for comb-type connectors

6 6 2 1 6 2 2

Part Number 83 30 0 494 159 81 69 0 416 257 90 88 6 619 041 90 88 6 619 042
WARRANTY INFORMATION

Covered under the terms of the BMW New Vehicle Limited Warranty. Defect Code Labor Operation: 63 21 92 79 00 00 56 867 Repair of an 8-pin connector for one rear light cluster, checking the connection of the other rear light cluster, fitting the additional earth line to both sides. Labor Allowance: Labor Operation: 6 FRUs Repair of the 8-pin connector for both rear light clusters, fitting the additional earth line to both sides. Labor Allowance: Labor Operation: 7 FRUs 00 56 183 Repair of an 8-pin connector for one rear light cluster, checking the connection of the other rear light cluster, fitting the additional earth line to both sides. Labor Allowance: Labor Operation: 7 FRUs Repair of the 8-pin connector for both rear light clusters, fitting the additional earth line to both sides. Labor Allowance: Sublet Code: Sublet Allowance: 9 FRUs 4 $1 for one side or $2 for two sides (locally sourced brown wire)

00 56 868

00 56 184

Note: The following explanations will spell out the correct use of the work times.

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Main Work:

Use this labor operation number when the only repair performed is the listed warranty repair. OR Use this labor operation number when other repairs or services are performed along with the listed warranty repair. Under no circumstances should both labor operation numbers be claimed. Attempts to claim both times will result in an unnecessary delay in claim processing and payment.

+Associated Work:

[ Copyright 2007 BMW of North America, LLC ]

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