im3crazy

This might make a good FAQ article since there are continuous questions regarding the various wiring diagrams and color codes. We could also provide a library of the wiring diagrams that have been collected on the forum.

DIN WIRING AND TERMINAL STANDARDS

Provided by im3crazy 3-16-2011

From Bosch Automotive Handbook, 3rd edition

We all have seen the number codes on our relay and other electrical terminals, but many

of us probably don't realize that these follow the DIN standard. Once you understand the standard it's much easier to troubleshoot the many grmelins that live in the '02s.

I've also included the color codes and gauge size crossover to AWG sizes.

It also might be helpful in future to include a common wiring scheme for the 02 models e.g. ground=brown, accessory/radio connection=violet/white; horn switch lead =brown/yellow etc.

Terminal Designations (Excerpts from DIN Standard 72 552)

The terminal designations do not identify the conductors, because a device with different terminal designations can be connected at the opposite ends of each conductor. If the number of terminal designations is not sufficient (multiple-contact connections), the terminals are consecutively labeled using numbers or letters whose representations of specific functions are not standardized.

WIRE COLORS

English .......................DIN (German)

Black . . . . . . . . . . . . . . . . . . . . .Sw

Blue . . . . . . . . . . . . . . . . . . . . . .Bl

Brown . . . . . . . . . . . . . . . . . . . ....Br

Green . . . . . . . . . . . . . . . . . . . . ..Gn

Gray . . . . . . . . . . . . . . . . . . . . . .Gr

Orange . . . . . . . . . . . . . . . . . . .....Or

Pink . . . . . . . . . . . . . . . . . . . . . .Rs

Purple . . . . . . . . . . . . . . . . . . . ...Vi

Red . . . . . . . . . . . . . . . . . . . . . ..Rt

Turquoise . . . . . . . . . . . . . . . . . ....Tk

White . . . . . . . . . . . . . . . . . . . . ..Ws

Yellow . . . . . . . . . . . . . . . . . . . ..Ge

Wiring Sizes: Metric - AWG

.5mm = 20AWG

.75mm = 18AWG

1.0mm = 16AWG

1.5mm = 14AWG

2.5mm = 12AWG

4mm = 10AWG

Ignition

1 . . . . . . . . . . .Ignition Coil, Distributor Low-Tension Circuit

Ignition Distributor With Two Insulated Circuits

1a . . . . . . . . . .to Ignition Point Set I

1b . . . . . . . . . .to Ignition Point Set II

Ignition Coil, Distributor

4 . . . . . . . . . . . High-Tension Circuit

Ignition Distributor With Two Insulated Circuits

4a . . . . . . . . . .Terminal 4, from Coil I

4b . . . . . . . . . .Terminal 4, from Coil II

15 . . . . . . . . . .Switch-Controlled Positive Downstream from Battery

(from Ignition Switch)

15a . . . . . . . . .In-Line Resistor Terminal Leading to Coil & Starter

Glow-Plug Switch

17 . . . . . . . . . .Start

19 . . . . . . . . . .Preglow

30 . . . . . . . . . .Line from Battery Positive Terminal (Direct)

31 . . . . . . . . . .Return Line from Battery Negative Terminal

or Ground (Direct)

31b . . . . . . . . .Return Line to Battery Negative Terminal or Ground Via

Switch or Relay (Switch-Controlled Ground)

Electric Motors

32 . . . . . . . . . .Return Line*

33 . . . . . . . . . .Main Connection*

33a . . . . . . . . .Self-Parking Switch-Off

33b . . . . . . . . .Shunt Field

33f . . . . . . . . .for Reduced-RPM Operation, Speed 2

33g . . . . . . . . .for Reduced-RPM Operation, Speed 3

33h . . . . . . . . .for Reduced-RPM Operation, Speed 4

33L . . . . . . . . .Rotation to Left (Counterclockwise)

33R . . . . . . . . .Rotation to Right (Clockwise)

*Polarity Reversal of 32/32 Possible

Starter

45 . . . . . . . . . .Separate Starter Relay, Output: Starter;

Input: Primary Current

Flasher Relay (Pulse Generator)

51 . . . . . . . . . .Input

49a . . . . . . . . .Output

49b . . . . . . . . .Output to Second Flasher Relay

49c . . . . . . . . .Output to Third Flasher Relay

Battery Switching Relay

50a . . . . . . . . .Output for Starter Control

Start-Locking Relay

50e . . . . . . . . .Input

50f . . . . . . . . .Output

Start-Repeating Relay

50g . . . . . . . . .Input

50h . . . . . . . . .Output

AC Generator (Alternator)

51 . . . . . . . . . .DC Voltage at Rectifier

51e . . . . . . . . .DC Voltage at Rectifier with Choke Coil

for Daylight Operation

Starter

52 . . . . . . . . . .Starter Control (Direct)

53 . . . . . . . . . .Wiper Motor, Input (+)

53a . . . . . . . . .Wiper (+), End Position

53b . . . . . . . . .Wiper (Shunt Winding)

53c . . . . . . . . .Electric Windshield Washer Pump

53e . . . . . . . . .Wiper (Brake Winding)

53i . . . . . . . . .Wiper Motor with Permanent Magnet & Third Brush (for Higher Speed)

55 . . . . . . . . . .Front Fog Lamp

56 . . . . . . . . . .Headlights

56a . . . . . . . . .High Beam with Indicator Lamp

56b . . . . . . . . .Low Beam

56d . . . . . . . . .Headlight Flasher Contact

57 . . . . . . . . . .Parking Lamps (in some export markets)

57a . . . . . . . . .Parking Lamps

57L . . . . . . . . .Parking Lamps, Left

57R . . . . . . . . .Parking Lamps, Right

58 . . . . . . . . . .Side-Marker Lamps, Taillamps, License Plate

& Instrument Illumination

58d . . . . . . . . .Rheostatic Instrument Illumination, Tail- & Side-Marker Lamps

58L . . . . . . . . .Left

58R . . . . . . . . .Right, License Plate Lamps

AC Generator (Alternator)

(Magneto Generator)

59 . . . . . . . . . .AC Voltage Output, Rectifier Input

59a . . . . . . . . .Charging-Armature Output

59b . . . . . . . . .Taillamp Armature, Output

59c . . . . . . . . .Stop-Lamp Armature, Output

61 . . . . . . . . . .Charge Indicator Lamp

Tone-Sequence Controller

71 . . . . . . . . . .Input

71a . . . . . . . . .Output to Horns I & II (Bass)

71b . . . . . . . . .Output to Horns 1 & 2 (Treble)

75 . . . . . . . . . .Radio, Cigarette Lighter

76 . . . . . . . . . .Speakers

77 . . . . . . . . . .Door Valve Control

Switches, Normally Closed (NC) Contacts & Changeover Contacts

81 . . . . . . . . . .Input

81a . . . . . . . . .First Output on NC-Contact Side

81b . . . . . . . . .Second Output on NC-Contact Side (NO Contacts)

82 . . . . . . . . . .Input

82a . . . . . . . . .First Output

82b . . . . . . . . .Second Output

82z . . . . . . . . .First Input

82y . . . . . . . . .Second Input

Multiple-Position Switch

83 . . . . . . . . . .Input

83a . . . . . . . . .Output (Pos. 1)

83b . . . . . . . . .Output (Pos. 2)

83L . . . . . . . . .Output (Left)

83R . . . . . . . . .Output (Right)

Current Relay

84 . . . . . . . . . .Input: Actuator & Relay Contacts

84a . . . . . . . . .Output: Actuators

84b . . . . . . . . .Output: Relay Contacts

Switching Relay

85 . . . . . . . . . .Output: Actuator (Negative Winding End or Ground)

Input: Actuator

86 . . . . . . . . . .Start of Winding

86a . . . . . . . . .Start of Winding or First Winding Coil

86b . . . . . . . . .Winding Tap or Second Winding Coil

Normally Closed (NC) Relay Contact & Changeover Contacts

87 . . . . . . . . . .Input

87a . . . . . . . . .First Output (NC-Contact Side)

87b . . . . . . . . .Second Output

87c . . . . . . . . .Third Output

87z . . . . . . . . .First Input

87y . . . . . . . . .Second Input

87x . . . . . . . . .Third Input

Normally Open (NO) Relay Contact

88 . . . . . . . . . .Input

88z . . . . . . . . .First Input

88y . . . . . . . . .Second Input

88x . . . . . . . . .Third Input

Normally Open (NO) Relay Contact & Changeover Contacts (NO Side)

88a . . . . . . . . .First Output

88b . . . . . . . . .Second Output

88c . . . . . . . . .Third Output

Generator/Alternator & Voltage Regulator

B + . . . . . . . . .Battery Positive Terminal

B - . . . . . . . . .Battery Negative Terminal

D + . . . . . . . . .Generator Positive Terminal

C - . . . . . . . . .Generator Negative Terminal

DF . . . . . . . . . .Generator Field Winding

DF1 . . . . . . . . .Generator Field Winding 1

DF2 . . . . . . . . .Generator Field Winding 2

Alternator

J........Excitation winding positive

K........Excitation winding negative

Mp.......Center point terminal

U, V, W . . . . . .Three-Phase Terminals

Turn Signals (Turn-Signal Flasher)

C . . . . . . . . . . .Indicator Lamp 1

C0 . . . . . . . . . .Main Terminal Connection for Indicator Lamp Not

Connected to Turn-Signal Flasher

C2 . . . . . . . . . .Indicator Lamp 2

L . . . . . . . . . . .Left-Side Turn Signals

R . . . . . . . . . . .Right-Side Turn Signals

Additional Wiring Color Coding

(earlier and later models)

Memory (+12v Constant)

Gray/Red

Ignition (+12v Switched) Violet

Ground (-) Brown

Illumination White/Blue

Dimmer (none)

Power Antenna White

S p e a k e r s

Right Front (+) Gray/White

Right Front (-) Gray/Brown

Left Front (+) Gray/Red

Left Front (-) Gray/Violet

Right Rear (+) Black/White

Right Rear (-) Black/Brown

Left Rear (+) Black/Red

Left Rear (-) Black/Violet

MORE DETAILS TO BE ADDED E.G BMW 2002 wiring color coding; various wiring diagrams; wire harness layout and sizing etc.

END

You sound like you are on the right track. What make and model is your alarm? can you post the wiring schematic that came with it, or provide the url for it. It also helps to do a simple wiring diagram.

My concern about your relay was if the relay itself could handle the power to the starter solenoid trip. It's important to know the contact rating for the relay. I thnk 500MA might be too small. The starter solenoid lead (2.5 Black wire from terminal 50 on ign switch) runs through your alarm relay disconnecting the circuit when in armed and when in alarm condition until reset with code/transmitter.

STOP! don't power up yet. If I read your spec correctly you will need a relay in the ignition switch to solenoid circuit. The 500 ma rating 1/2 amp is not enough to handle the solenoid pilot draw. You can use a 3 amp @12vdc relay triggered from the alarm output to handle the current. without this relay u will likely immediatly or eventually burn out the on-board relay/circuit.

If you're primarily concerned about getting rear ended try these. Ive mounted two at the headliner level with a "trailer" module that gives me stop/tail/turn. These are freakin lasers and tailgaters back right off!

http://www.commandelectronics.com/led-tail-lights.html

WHen I've seen this it's been a failure of the blinker relay - IIRC the lead for the dash indicator is fed from the relay output in the blinker - see 31 in diagram attached and lead #8 which lights E on the dash pod. Failed components or incorrect flasher substitutes can also cause the blinker to continuously cycle.

BMW 2002 Electric Diagram.pdf

It's always tough to value a vehicle, but comprables are always helpful. Check out the 2002AD sites ads. They are usually priced a little higher than what they get, but it's close. Ebay will also sell you their recent sale info on similar cars, I believe, I've never done that.

http://www.2002ad.com/pages/carsforsale.cfm

Best of luck with the eventual sale.

Dave in Baltim02e MD

They are prob from the emissions control relays - check this out and compare to the harness shown:

http://www.bmw2002faq.com/content/view/18/32/

good luck.

Check out this link from Pierre on the FAQ:

http://home.roadrunner.com/~pchamaa/2002_auxilliary_lamp_brackets.htm

I'm thinking of changing over to these because my bumper mounts vibrate/ oscillate too much- it does however get driver attention way down the road.

Check out this link from Pierre on the FAQ:

http://home.roadrunner.com/~pchamaa/2002_auxilliary_lamp_brackets.htm

I'm thinking of changing over to these because my bumper mounts vibrate/ oscillate too much- it does however get driver attention way down the road.

Purchased a 1969 owners manual and service location booklet from eastsidebimmer in Indianapolis. As advertised and fast ship out. Thanks.

It sounds like the resistance wiring in the tank assembly has shorted. You can prove this out by removing the sender unit and measuring the resistance reading with a multimeter, or the gas gauge. You can immerse the sender in kerosene safely and move it up and down to watch the resistance response, or the gas gauge. Once you know the linearity or not of the reading, you can make a decision to replace the sender or seek further cause.

A little late on this but I purchased in late Summer a replacement 5 speed Getrag for my 02 from Al and the condition was as stated (perfect), clean, and well packed for shipping. Great price too! My second purchase from him - first was seatbelt upgrades which also were done with high level of craftsmanship and detail.

Thanks.

Dave

I can confidently recommend Smith Upholstery and Auto Glass in Baltimore whom I have used successfully for 35 years. Latest work was a custom headliner for my 98 M3. The job was done to perfection, and far exceeded the original.

http://www.smithautoglass.com/home.nxg

Dave in Baltimore

It doesn;t get much better than Bill's FAQ on decal placement:

http://www.bmw2002faq.com/content/view/95/32/

Dave in (snowy, salty, and wet) Baltimore

Also had this happen due to exhaust pipe/end can heating up tank. I had to install the later heat shield and it solved the problem, I measured the outlet gas temp at over 110 deg F.

I agree with good locksmith and also suggest .... yes, the dealer should be able to cut key from VIN.

I'm interested in the two door rubber plugs that depress the door switch for the interior light if you have them. I'm also interested in the Alpina wheels if u still are selling. I'm in Pikesville.

I have to agree about the over torquing. Just tried to change over to snow tires and couldn't get the nuts off. Broke two sockets with a breaker bar and extension and decided to stop before I broke off the studs.

This was the first year I had the local shop mount my summer tires- it was a mistake. Took it back and got them to pull them off- they were on at about 110-120 ft lbs. The mechanic swore that's what they regularly use. This cannot be right- I thought the spec was 45-55 ft lbs for these.

Wtb long neck tank that fits 1970 opening. Non tii. Shipng to baltimore md us. Need no rust in/out clean tank. Thanks.

What's the condiiton of the tank in/out? Any pics? I can pickup from baltimore if its clean and will fit my 1970. Thanks.

Did u sell the gas tank? I need a clean no rust long neck that fits my 1970 02. Shipng to baltimore md us. Paypal ok. Pics would b great. Thanks.

What year and condition is gas tank? I need a long neck that fits my 1970. Whre r u shippng from. What r u asking? Pics would b great. Thanks.

Dave in baltimore

I have used the 3M citrus based product with a rough scotchguard pad- slow going and marginally effective.

Also have used the older 3M petroleum-based product (item 08984).

This works very well, but requires skin and breathing protection - it has benzenes in it which are a known cancer risk.

Any product containing these is an equivalent to the 3M product- Ingredient listed % by Wt

XYLENE

NONANE

OCTANES (ALL ISOMERS)

ETHYLBENZENE

TOLUENE

BENZENE

Don't drink this stuff, but you could probably add it to your gas tank with good octane improvement

Sounds like u toasted the heater bearings (squeal) and motor windings (smoke), maybe also the heater resistor assembly (more smoke). High resistance may have been created by water shorting out components.

Looks. Like I'll have to get my 245 getrag rebuilt or replaced. Not happy but moving forward. Any suggestions for rebuilds or good used suppliers. I know of metric mechanics but hoping to find cheaper approach. I'm in Baltimore . Thanks.