When I first got broken wires in the wiring loom I just soldered the wires back together but that fix didn't last. Under a year and I got more broken wires. So I decided to pull the wiring harness and replace the section that get bent each time you open or close trunk. Since Imageshack is having some issues I made it into a PDF. Due to forum restrictions I had to compress it quite a bit so quality isin't the best possible. Anybody got any comments?
Update: I uploaded a new version of it on filefactory. The PDF is now over 4 MB, so the quality should be better. Link
Update: New link
Last edited by Spirit Force; 03-23-2015 at 04:22 PM. Reason: New link to the guide
The wires aren't too short, they just get bent too much. I think the original wiring is PVC insulated, which doesn't take too well being bent that much regularly. Just take a look at the rubber loom when you close the trunk. Wires get twisted into U shape.
May have to splice in some very finely-stranded wires.
Ed in San Jose '97 540i 6 speed aspensilber over aubergine leather. Build date 3/97. Golden Gate Chapter BMW CCA Nr 62319.
Excellent write up. What were the symptoms that made you check the harness? It seems that this only affects blue cars lol.
- - - Updated - - -
Uploaded new version on filefactory. It's a better quality (over 4 MB). Added some more info and few new pictures.
I'd love to see this too. Both trunk lights out. Verified broken wiring harness at the pass side trunk lid hinge. For the moment the remote release still works, both at the button at the driver's door jam and via the remote key fob.
I'll keep an eye out for a fixed link .
- - - Updated - - -
Well this is interesting. Hopefully we're talking about Part #4 in the diagram, not Part #3...
For that push off the cliff, this one GOES211...
New to the forum, just bought a 2003 530i and seem to have all the typical issues for this model/year. Found the trunk wiring harness issue while replacing tag lights. Has anyone found a good fix for this? Right now all I know to do is cut wires one at a time, butt solder together, and cover with heat shrink. Not much extra length in wire to play with.
I was able to fix the trunk wiring harness this weekend. I had to cut each wire and solder back with a inline joint. I have too say probably the worst soldering job I have done in my life. It is very hard to keep the wires together in a vertical position in the corner of the trunk with soldering iron in one hand and solder in other. Not to mention it felt like 120 degrees outside with humidity 1000%.....LOL The design for that harness is the worst I have seen. I recommend carefully slicing the rubber harness length wise the entire length, pulling all the wires out and doing the repair. Make sure to use heat shrink on each wire. When done you will be able to slip the wires back into the harness and use 3M Scotch 33 black tape to wrap around entire length of harness.
I uploaded it again, but it will dissappear after 100 days, if noone downloads it. Anyone got any suggestions on a good upload site that has no expiration?
Need a link
2005 X5 4.8is Le Mans Met Blue
2003 525iT TiSi
2002 M5 TiSi
1998 528i Champagne
Former Garage Highlights
2004 325iTs (2x)
1971 Dodge Dart Sport "Light Package"
1970 Dodge Challenger T/A 340 Six Pack Alpine White
1970 Dodge Challenger T/A 340 Six Pack Go Man Go Green
1969 Road Runner 383