61 13... Butt connector for repairing a plug connection

WARNING: This page does not describe the selected car, but rather 50 other vehicles, including the 2016 BMW M5, 2016 BMW ActiveHybrid 5, 2016 BMW 550i xDrive, 2016 BMW 550i, and 2016 BMW 535i xDrive. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

IMPORTANT:

Identify cause of damage (e.g. sharp-edged body components, faulty electrical loads, jammed mechanisms, corrosion caused by ingress of water, etc.).
Read out fault memory
Eliminate cause of damage.
Disconnect battery negative terminal
Make sure that no safety-related system according to circuit diagram (e.g. antilock braking system, active rear-axle kinematics, airbags, etc.) are influenced. Otherwise replace faulty wiring harness or use repair cable (sourcing reference: BMW Parts Department)
Carry out function test and read out fault memories again
Eliminate new faults if applicable and clear fault memories

NOTE: The repair range IV for vehicle electrical system contained the required special tools and individual parts for retrofitting and repair work with the aid of fan connectors.
The case can no longer be ordered. Order individual parts for wiring harness repair through BMW Parts Department.

Fig 1: Identifying Special Tools Kit

Courtesy of BMW OF NORTH AMERICA, INC.

Choose repair kit.

Example: Repair kit, circular connector system D 2.5.

Fig 2: Identifying Circular Connector And Special Tools Kit

Courtesy of BMW OF NORTH AMERICA, INC.

Remove following parts:

Pre-packaged end of cable with requisite wire cross-section
Crimp connector for selected wire cross-section
Shrink-fit hose

Fig 3: Identifying Crimp Connector For Selected Wire Cross-Section And Shrink-Fit Hose
Courtesy of BMW OF NORTH AMERICA, INC.

Open secondary lock on housing.

Mark damaged contact (4) with socket number of housing and press it out of housing using appropriate special tool contained in special tool set 61 0 300 ).

See repair instructions

Notes for OPENING CONTACTS AND LOCKS of different plug contact systems.

Fig 4: Identifying Mark Damaged Contact With Socket Number Of Housing

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT:

Check maximum length of repair cable
If more than one wire is to be repaired, the individual interfaces must be offset so that the wiring harness is not too thick at the repaired point.

Adhere to following procedure:

Cut off wire with faulty contact at point which is easily accessible
Strip insulation from end of wire at wiring harness end
Cut preassembled wire end to length and strip insulation

Fig 5: Identifying Wire Stripper
Courtesy of BMW OF NORTH AMERICA, INC.