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: Google drive link, so should be good from now on.
Last edited by Spirit Force; 08-07-2018 at 08:38 AM. Reason: Now hosted on google drive
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.
Thank for the contribution. I'll tow this to the DIY section after comments.
Fyi, first link in PDF is broken (at least for me).
Excellent write up. What were the symptoms that made you check the harness? It seems that this only affects blue cars lol.
Thanks for the heads up. I first began writing it on the forum and only discoved the imageshack wasn't working when I was almost ready. I couldn't upload pictures to imageshack, so I just copy pasted it to MS Word. It seem that I forgot to fix the first link after that. Oh well I'll be doing some minor fixing on it anyways. I'll upload a better quality PDF to imageshack and put a link for it in the first post. How long can I edit the first post? Can I edit it after it's been towed to DIY section?
Thanks. The issues were: trunk wouldn't open via remote, inside switch, or the trunk switch. Only turning the key 90 degrees would open it. What a pain in the ass to use the key each time! Mine isin't blue it's Cosmosschwarz
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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 .
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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
Current Garage Highlights
2003 525iT TiSilver
2002 M5 TiSilver
1998 528i KASCHMIRBEIGE METALLIC (301) (Goldie)
Former Garage Highlights
2005 X5 4.8is
2004 325iTs (2x)
1973 Pantera L
1971 Dodge Dart Swinger "Lite Package"
1970 Dodge Challenger T/A 340 Six Pack Alpine White
1970 Dodge Challenger T/A 340 Six Pack GoManGo Green
1969 Road Runner 383
1968 Barracuda Formula S 340 Sea Foam Green
Both links are dead.
I did this fix too. Essentially I soldered a replacement wire to the top of the broken one and then used the old wire as a fish to pull the new one through from top to bottom. I then spliced top and bottom using solder/shrink wrap. Rinse/repeat. I did them two at a time and on the last set, I pulled through a backup camera cable as well for extra credit...
tip:
after doing the fix? When possible,limit the number of times you have to FULLY open the trunklid when placing something in/getting something out. Less stress on the wire loom
OK, anyone have this PDF? I'll happily host it in my Google Drive...
Does anyone have instructions specifically for installation of the Sencom 2016065 harness repair kit in the E60? Sencom has a video up for the E61 repair but not the E60...
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