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SB-10043927-2032
SI M65 08 03
Audio, Navigation, Monitors, Alarms, SRS

March 2012
Technical Service

This Service Information bulletin supersedes SI M65 08 03 dated July 2006.
designates changes to this revision
SUBJECT

Airbag Warning Light Is ON: MRS FC 02, 03, 05, 06
MODEL

R50 (Cooper)
R53 (Cooper S - Manual Transmission Only)
Vehicles from start of production to February 17, 2003
SITUATION

The customer may complain that the airbag warning light is on, and the following faults are stored in the
MRS (Multiple Restraint System) control unit:


02 – Driver’s side belt tensioner ignition circuit



03 – Passenger’s side belt tensioner ignition circuit



05 – Driver’s side seat airbag ignition coil



06 – Passenger’s side seat airbag ignition coil

CAUSE

Faulty crimping of contacts at the seat connectors
NOTE: The first performance of the repair procedure listed below, to correct this specific issue, is
covered on eligible affected vehicles for 10 years/150,000 miles, whichever occurs first.
All subsequent repairs would then be covered by the remaining portion of any applicable standard or
program coverage that may apply.
The customer was provided with an extended warranty sticker that was to be affixed in page 25 of their
Service and Warranty Book. Please see the attached customer letter.
AFFECTED MODELS

Model

Chassis Number Range

Cooper – Manual (R50)

TC30047 – TC43963

Cooper S – Manual (R53)

TD50072 – TD65791

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Cooper – Automatic (R50)

TE10037 – TE17624

PROCEDURE

NOTE: Please be sure to follow the procedure as described below. Analysis of parts returned so
far shows:


Connectors are being returned disconnected. (The connectors must remain connected: see
steps 4 and 5.)



Connector wires are cut too close to the connector. (The wires must be cut 100mm from the
connector: see steps 4, 5, 10 and 11.)



There is no DIS printout accompanying the returned parts. (A DIS printout, showing which
connector failed and its fault codes, must be included.)



Connectors for one vehicle are being returned in more than one bag. (Place all connectors in
one return bag.)

Failure to follow these procedures will result in the warranty claim being debited.
If one of the faults mentioned above is stored:
1.

Perform a vehicle test using ISTA/D (Integrated Service Technical Application) and complete
all the corresponding test module-related fault codes and the printout that shows the failed
connector and its stored fault codes. Then replace the wiring to the respective belt tensioner and
side airbag for the seat with the repair harnesses, as described below.

2.

Disconnect the battery. Always comply with the safety instructions when handling airbag
devices as outlined in ISTA Repair Instruction REP 72 00…
The following tools will be needed in order to perform this repair correctly:
• Pliers (without die plate) 61 9 041
• Die plate for pliers 61 9 042
• Wire strippers 61 9 043
• Hot air blower

3. Remove the (4) mounting screws from the front
seat with the stored fault.
The illustration shows the (2) front screws.

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4. Raise the seat at the front (1).

5. Locate the yellow side airbag connector (DO
NOT DISCONNECT).
Cut the wire as shown, 100mm from the
connector (A).

6. Locate the blue seat tensioner (DO NOT
DISCONNECT).
Cut the wire as shown, 100mm from the
connector (A).

7. Disconnect the remaining connectors (4) and (5),
and remove the seat from the vehicle. Connector
(4) may not be on all vehicles.

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8. Install the new cable tie with holder (1) (P/N 61
13 0 302 824) and fit to the carrier (2). Remove
the cable tie for later use.

9. Release the connector housing (1) by turning it
slightly.
10. Release the seat wiring harnesses (2) for the side
airbag and seat belt tensioner from the retainers
(3).

11. Locate the yellow side airbag connector (2). Cut
the wire as shown, 100mm from the connector
(A).
Tag the removed part with the VIN. Do not
scrap the removed part; it may be necessary
to ship the part to BMW for analysis (DO
NOT DISCONNECT THE CONNECTOR).

12. Locate the blue seat tensioner connector (3). Cut
the wire as shown, 100mm from the connector
(A).
Tag the removed part with the VIN. Do not
scrap the removed part; it may be necessary
to ship the part to BMW for analysis (DO
NOT DISCONNECT THE CONNECTOR).
Mark the defective connector(s), and then put all the removed parts and ISTA printout together in a
plastic bag.
Preparing seat wiring harnesses for repair

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13. Shorten the outer sheath of the seat
wiring harnesses by approximately
50 mm from the wire ends. Take
care not to cut the wiring. Seal the
outer sheaths to the wires using
fabric adhesive tape.
14. Cut the seat wiring harnesses for
the side airbag (1) and belt
tensioner (2) to offset lengths with
the following dimensions (cut only
[1] wire of each wire pair):
Seat wiring harness for side airbag
(1):
Violet/white triggering circuit
wire A=30 mm
Seat wiring harness for belt
tensioner (2):
Green triggering circuit wire A =
30 mm.

15. Strip the ends of the triggering
circuit wires on the seat wiring
harnesses to a length of 4 mm.
Install the shrink tube (1) (P/N 61
13 0 149 206) over the wires.

16. Swap over the retainer clips from
the old harness connectors to the
new repair harness connectors.
17. Connect the repair harness sections
(1) and (2) together for both the
seat side airbag repair harness (P/N
61 12 6 937 521) and the seat belt
tensioner repair harness (P/N 61 12
6 937 522). Fold the repair harness

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sections (1) and (2) at the
connection to form an “S” shape.
Secure with cable ties (3) (P/N 61
13 0 141 326). Take care to note
the position of the cable fasteners.
Do not use Stabilant 22 or any
other contact enhancer on the
connections.

18. Shorten the outer sheaths of the
repair wiring harnesses to B = 100
mm. Seal the outer sheaths to the
wiring harnesses using fabric
adhesive tape.
19. Cut the repair wiring harnesses for
the side airbag (1) and the belt
tensioner (2) to offset lengths with
the following dimensions:
Note: the wire colors are different
based on the date of manufacture
of the repair harness.
Late production repair wiring
harness
Repair wiring harness for side
airbag (1):
Black/White triggering circuit
wire A=40 mm
Violet/White triggering circuit
wire C=70 mm
Repair wiring harness for belt
tensioner (2)
Black triggeringcircuit wire A=40
mm
Green triggering circuit wire C=70

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mm
Early production repair wiring
harness
Repair wiring harness for side
airbag (1):
Brown triggering circuit wire A =
40 mm
Yellow triggering circuit wire C =
70 mm
Repair wiring harness for belt
tensioner (2)
Yellow/Brown triggering circuit
wire A=40 mm
Yellow/Red triggering circuit wire
C=70 mm

20. Strip the ends of the shortened
triggering circuit wires on the
repair harnesses to a length of 4
mm.
21. Crimp a butt connector (1) (P/N 61
13 0 149 205) to each seat wiring
repair harness (2) wire.

22. Crimp the repair wiring harnesses
to the seat wiring harnesses in
accordance with the attachment
Chart A. Make sure that the proper
wire colors are used, based on the
manufacturing date of the repair
harness.

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23. Slide the shrink tube (1) over the
crimp connection and heat up with
a hot air blower until glue escapes
onto the wires, as indicated by
arrows.
24. Using fabric adhesive tape, wrap
the exposed harness.

25. Press the wiring harnesses into the
retainer as indicated by the arrow.
26. Secure the connector for the belt
tensioner (1) and side airbag (2)
onto the carrier.
27. Secure the repair wiring harnesses
to the retainers (3) with cable ties.

Preparing the repair wiring harnesses for connection to the body wiring harness
28. Shorten the repair wiring harness
for the side airbag (1) and seat belt
tensioner (2) as follows:

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29. Shorten the outer sheaths of the
repair wiring harnesses to A = 150
mm.
30. Cut the repair wiring harnesses for
the side airbag (1) and belt
tensioner (2) to offset lengths with
the following dimensions:
Note: The colors of the triggering
circuit wires for the repair
harnesses have not changed.
Repair wiring harness for side
airbag (1):
Brown triggering circuit wire
D=50 mm
Yellow triggering circuit wire
E=80 mm
Repair wiring harness for belt
tensioner (2):
Yellow/Brown triggering circuit
wire B=110 mm
Yellow/Red triggering circuit wire
C=140 mm

31. Strip the ends of the shortened
triggering circuit wires on the
repair harnesses to a length of 4
mm.
32. Crimp a butt connector (1) (P/N 61
13 0 149 205) to each seat wiring
repair harness (2) wire.

Preparing the body wiring harness for repair

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33. Remove the fabric adhesive tape
(1) from the vehicle wiring harness
and slide back the sheathing (2)
by approximately 300 mm.
34. Fix the sheathing in place with a
cable tie or fabric adhesive tape.

35. Cut the body wiring harness for the
side airbag (1) and belt tensioner
(2) to offset lengths with the
following dimensions:
Body wiring harness for side
airbag (1):
Brown triggering circuit wire
A=50 mm
Yellow triggering circuit wire
B=80 mm
Driver’s side body wiring harness
for belt tensioner (2):
Yellow/Brown triggering circuit
wire C=110 mm
Yellow/Red triggering circuit wire
D=140 mm
Passenger side body wiring
harness for belt tensioner (2):
Blue/Brown triggering circuit wire
C=110 mm
Blue/Red triggering circuit wire
D=140 mm

36. Strip a length of 4mm from the end
of each wire.

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37. Slide a shrink tube (1) over each
wire.

Connecting the repair wiring harness to the body wiring harness

38. Place the seat in the vehicle and tilt
back towards the rear seat.
39. Crimp the wiring harnesses (1)
together in accordance with the
attachment Chart B.

40. Slide the shrink tubing (1) over the
crimp connections and heat up
using a hot air blower until glue
escapes onto the triggering circuit
wires, indicated by arrows.

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41. Slide the wire sheathing (1) over
the wiring harness and secure with
fabric tape (2).
42. Reinstall the front seat.
43. Reconnect the battery.
44. Clear the fault memory.

PARTS INFORMATION

Part Number

Description

Quantity*

61 12 9 118 130

Repair harness for side airbag

1

61 12 9 118 132

Repair harness for belt tensioner

1

61 13 1 377 134

Cable tie

4

61 13 8 353 746

Butt connector

8

61 13 1 379 833

Shrink tubing

8

61 13 6 916 946

Cable tie with holder

2

*Quantity is for the repair of one seat only
WARRANTY INFORMATION

The warranty coverage for this specific issue on eligible affected vehicles is 10 years/150,000 miles,
whichever occurs first.
Defect Code

61 12 94 79 00

A. Repairing One Front Seat Only
Labor Operation:

Labor Allowance:

Description:

00 56 127

Refer to KSD2

Install repair cable for seat belt tensioner
and repair cable for side airbag, left or right
(one front seat)

Labor operation code 00 56 127 is a Main labor operation. If you are using a main labor code for another
repair, use the plus code labor operation 00 56 770 instead.
or
B. Repairing Both Front Seats

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Labor Operation:

Labor Allowance:

Description:

00 56 126

Refer to KSD2

Install repair cable for seat belt tensioner
and repair cable for side airbag, left and
right (both front seats)

Labor operation code 00 56 126 is a Main labor operation. If you are using a main labor code for another
repair, use the plus code labor operation 00 56 768 instead.
Refer to KSD2 for the corresponding flat rate unit (FRU) allowance. Enter the Chassis Number, which
consists of the last 7 digits of the Vehicle Identification Number (VIN). Click on the “Search” button,
and then enter the applicable flat rate labor operation in the FR code field.
ATTACHMENTS

view PDF attachment M650803_Customer_Letter.
view PDF attachment M650803_Wiring_Info.
[ MINI, a division of BMW of North America, LLC
Copyright © 2012 BMW of North America, LLC ]

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