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E46 M3 (2001-2006) Engine: S54 - Max Hp: 333 hp at 7,900 rpm / 262 lb/ft at 4,900 rpm
Total Produced: 45,000+ - Years Produced: 2001 to 2006.


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Old Wed, Sep-09-2009, 01:50:03 AM   #1
Beach_Bum
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Default Anyone Have a Part # for This or Some Advice? (Seat Belt Pyrotechnic Plug)

I'm putting my stock seats back in the car and when I get to the driver side, I realize that when I originally installed the PPs, the guy that was helping me cut this harness wire really short, as you can see below. I'm having an impossible time wrapping the wires because they just aren't long enough and the wire is pretty thick. Is there any way to get lower on the wires? I looked at the plug and it doesn't appear to come apart and I definitely don't want to break it.


What are my options here? I thought about soldering or maybe ordering a new plug but can't seem to find the part number on realoem.com. Maybe buy some thinner wire and to bridge the gap between the two and try to attach it that way?

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Old Wed, Sep-09-2009, 02:30:07 AM   #2
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Maybe some crimp-on or heat shrink connectors from Radio Shack?
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Old Wed, Sep-09-2009, 02:32:06 AM   #3
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I'd just find someone to solder on some wire for you so they are easier and safer to manage at this point.

Also take off the black cover, simply slide it out, this may give you extra room.
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Old Wed, Sep-09-2009, 04:42:52 AM   #4
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Sorry this is so long, but this is the fix!!!
Notes

Repair Instructions for E46

Vehicles concerned:
E46
Manufacturing period: from start of series production to April 2002

Procedure:

1. Connect BMW diagnostic system (DISplus or GT1) to the vehicle.

2. Read off fault memory.

The following fault codes could be stored in the fault memory of the airbag control unit, depending on manufacturing period and model:

E46 Coupe US to March 1999
E46 to September 1999

^ "05 - Driver-side belt tensioner triggering circuit"

^ "06 - Passenger-side belt tensioner triggering circuit"

E46 Coupe US from March 1999
E46 from September 1999

^ "02 - Driver-side belt tensioner triggering circuit"

^ "03 - Passenger-side belt tensioner triggering circuit"


3. Disconnect the vehicle battery.

4. Fit repair wiring harness

Important: Comply with safety instructions when handling airbag modules and pyrotechnic belt tensioners.

The minimum transition resistance must be achieved when the repair wiring harness is fitted. For this reason it is essential that the hotspots in the Repair Instructions are observed.

Service Information bulletin SI 61 01 99 (397) "Airbag, Repair Instructions for triggering circuits" remains valid for damaged or defective wires and connectors in the triggering circuits of the airbag system.

The following special tools from repair set IV for vehicle electrics (order no. 61 9 020) are needed for professional repairs on the wiring:

- Hand-held stock (without die) (order no. 61 9 041)

- Die for hand-held stock (order no. 61 9 042)

- Insulation strippers (order no. 61 9 043)

Note: All instructions needed on using the special tools are described in the Operating instructions / volume 1 (order no. 61 9 029).

A conventional workshop hot-air blower is also required.

Remove the front seat concerned.








Unlock and separate connector (1) on the belt tensioner.

Pull seat wiring harness (2) from retainer (3).







Unclip retainer (1) from carrier (2) and unthread seat wiring harness (3).

Note: Retainer (1) can be reused.

Pull the cover cap from the central seat connector.







Cut off the two belt tensioner triggering circuit wires (1) yellow/brown and yellow/red on the seat wiring harness at the yellow connector housing (2).

Refit the cover cap.

Note: On seats without positioning motors and seat heating, the connector is not required.

Prepare the repair wiring harness as follows:







Cut the blue wire on the repair wiring harness section (1) to different lengths (A = approximately 30 mm).

Strip 4 mm at the ends of the wires.

Cutting and stripping wires







Crimp-connect butt joint (1) for wire cross-sections of 0.35 to 0.50 mm2 to the two stripped ends of repair wiring harness section (2).

Crimping buffer pieces

Connect the repair wiring harness sections with the connector.







Plug angled connector (1) onto the belt tensioner and lock.

Press repair wiring harness section (2) into retainer (3).







Clip repair wiring harness section (3) into carrier (2) with retainer (1).







Important: Repair wiring harness section (1) must be routed and secured so that it is free of tension.

Route repair wiring harness section (1) under the seat and into the plastic clips (2) in the order shown.







Fold repair wiring harness sections (1) and (2) at the connector to form an "S" shape.

Note: The position of the cable ties (3) on the "S" shape section is determined by subsequent fastening to the carrier.







Secure "S" shape (1) on carrier (2) of central seat connector with two crossed cable ties (3).

Note: When securing the "S" shape, the crossed cable ties (3) should securely connect the repair wiring harness sections to the connector housing.







Connect the butt connector on the repair wiring harness section (4) to the BMW diagnostic system through multifunction cable 1 (MFK 1):

(1) MFK 1 from BMW diagnostic system

(2) Double-ended banana plug

(3) SAGK4 tapping clips, black and red (DIS measuring probe set 61 1 410)

(4) Repair wiring harness section


On the BMW diagnostic system, select "Multimeter" measuring method with resistance/ohms submenu.

Read off measured value.
Setpoint value: 1 to 6 ohms

Note: If the setpoint value is not achieved, replace the belt tensioner and return the removed part together with the tester printout.

Continue fitting the repair wiring harness.







Place the front seat in the vehicle and tilt it back to the rear seat.

Remove the cover cap from connector housing (1) on the vehicle wiring harness and remove the twisted belt tensioner triggering circuit wires (2) yellow/brown and yellow/red from the connector housing.

Close connector housing (1) again with the cover cap.







Remove the fabric adhesive tape from the vehicle wiring harness and slide back insulating sleeve (1) approximately 300 mm.

Shorten yellow/brown triggering circuit wire by A = 250 mm and yellow/red triggering circuit wire by B = 220 mm.

Strip 4 mm of the triggering circuit wires.

Cutting and stripping wires







Slide heat-shrink sleeves (1) over the triggering circuit wires.







Crimp butt connector on repair wiring harness section (1) with triggering circuit wires.

Brown wire with yellow/brown
Blue wire with yellow/red

Crimping buffer pieces







Slide heat-shrink sleeves (1) over the crimped connections and heat with hot-air blower until glue escapes onto the wires.

Butt connector for repairing connector

Slide insulating sleeve (1) over the repair and fix to the vehicle wiring harness (3) with a cable tie (2).

Connect seat connector (1).

Install the front seat concerned.

5. Connect vehicle battery.

6. Clear the fault memory.
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Old Wed, Sep-09-2009, 01:41:29 PM   #5
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Quote:
Originally Posted by LightWerkz View Post
I'd just find someone to solder on some wire for you so they are easier and safer to manage at this point.

Also take off the black cover, simply slide it out, this may give you extra room.
So the black cover (with the wires hanging out) does slide off? That will make my life much easier. I tried, somewhat, to get it off last night, but didn't want to force/break it. Thanks!

Quote:
Originally Posted by Oldman MZ3 View Post
Sorry this is so long, but this is the fix!!!
Wow, where did you find that? Thanks
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Old Wed, Sep-09-2009, 01:43:40 PM   #6
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Yes it does, simply push up on the small tabs on the side (both sides) and it slides right off.
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Old Wed, Sep-09-2009, 02:05:09 PM   #7
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Quote:
Originally Posted by LightWerkz View Post
Yes it does, simply push up on the small tabs on the side (both sides) and it slides right off.
You just made my day LOL Thanks again
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Discussing Buying or just bought an E46/M3 - what you should know: in the E46 M3 (2001-2006) Forum - Engine: S54 - Max Hp: 333 hp at 7,900 rpm / 262 lb/ft at 4,900 rpm
Total Produced: 45,000+ - Years Produced: 2001 to 2006. at BMW M3 Forum.com (E30 M3 | E36 M3 | E46 M3 | E92 M3 | F80/X)