51 11... Additional work, pedestrian protection sensor

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NOTE: In vehicles up to version 25.03.2010 , certain additional work needs to be performed before the pedestrian protection sensor can be replaced.
The following list provides an overview of the additional work. Check that the additional work has been performed. If this additional work has not yet been performed, complete steps 1, 2, 3, 6 and 7.

New wiring harness installation arrangement (route wiring harness behind washer jet for headlight cleaning system, secure wiring harness).
Reworking of support for bumper trim (sand away knurled surface structures, deburr edges).
Installation of new spare parts (top impact absorber, pedestrian protection sensor).
Installation of spray guard lid at top impact absorber.
Securing of top impact absorber at support for bumper trim.
SA823 only (variant for hot countries): Trim of air duct of engine oil cooler at front left.
If additional work has not been performed yet: Carry out vehicle programming and encoding.

IMPORTANT: If the active pedestrian protection is deployed, all actuators must be replaced:

Replace active engine compartment lid lock on left and right . See 51 23 101 REMOVING AND INSTALLING/REPLACING LEFT ACTIVE ENGINE COMPARTMENT LID LOCK or 51 23 111 REMOVING AND INSTALLING/REPLACING RIGHT ACTIVE ENGINE COMPARTMENT LID LOCK
REPLACE ACTUATOR ON LEFT AND RIGHT

New wiring harness installation arrangement:
Disconnect plug connection (1) and unlock connector of front panel.

Feed out wiring harness (3) in front of hose for headlight cleaning system (2).

IMPORTANT: Check wiring harness (3) for damage!

Fig 1: Identifying Front Panel Connector
Courtesy of BMW OF NORTH AMERICA, INC.

Re-route wiring harness (1) . Route wiring harness (1) behind washer jet for headlight cleaning system (2) and hose for headlight cleaning system (3).

Clip in cable strap (5) on front panel. Secure wiring harness (1) with cable strap (5).

Lock connector (4) on front panel and lock plug connection.

Fig 2: Identifying Front Panel Cable Strap And Connector
Courtesy of BMW OF NORTH AMERICA, INC.
Rework support for bumper trim:
Grind off knurled surface structures (1) on left and right of bumper trim support (2) to remove burrs.

Fig 3: Supporting Bumper Trim
Courtesy of BMW OF NORTH AMERICA, INC.

Fully deburr bumper trim support (2) on left and right in area (1).

Fig 4: Identifying Bumper Trim Support Area
Courtesy of BMW OF NORTH AMERICA, INC.
New spare parts:
Insert new pedestrian protection sensor (1) part number 65 76 9 240 549 in new top impact absorber (3) part number 51 11 7 200 707.

The pedestrian protection sensor (1) must be fully locked in top impact absorber (3).

IMPORTANT: Before installation check the engagement of latch mechanism of the pedestrian protection sensor (1) in retaining lugs (2) over the entire length.
Before mounting, check top impact absorber for damage to retaining lugs (4). Do not install damaged top impact absorber.

Fig 5: Identifying Pedestrian Protection Sensor In Retaining Lugs
Courtesy of BMW OF NORTH AMERICA, INC.
Spray guard lid:
Mount lid (spray guard) (1) on right on top impact absorber (3) and secure with adhesive tape (2).

IMPORTANT: Water drains of lid (spray guard) (1) must not be taped over.

Fig 6: Identifying Pedestrian Protection Sensor And Adhesive Tape
Courtesy of BMW OF NORTH AMERICA, INC.
Securing of top impact absorber at support for bumper trim:
Mount top impact absorber (1) on support for bumper trim. First attach top impact absorber (1) at bottom and then press it in place as you move up.

Lock plug connection of pedestrian protection sensor.

Secure top impact absorber (1) in area of washer jet for headlight cleaning system on support for bumper trim with cable strap (2).

IMPORTANT: Lock of cable strap must be located at bottom of top impact absorber.

Fig 7: Installing Top Impact Absorber On Bumper Trim Support
Courtesy of BMW OF NORTH AMERICA, INC.
Air duct of engine oil cooler (only in vehicles with SA823 variant for hot countries):
Remove air duct of engine oil cooler at front left (1).

Cut air duct of engine oil cooler at front left (1) at marked area (2).

Dimension A = 60 mm

IMPORTANT: Cut along the solid line; the dashed line is for orientation only.
Bridge (3) must not be damaged.

Fig 8: Identifying Engine Oil Cooler Dimension
Courtesy of BMW OF NORTH AMERICA, INC.
Vehicle programming:
Delete fault memory.

Carry out VEHICLE PROGRAMMING AND ENCODING .