61 12... Replacing positive battery cable with safety battery terminal

NOTE: After activation of the safety battery terminal as a result of an accident, the entire positive battery cable does not have to be replaced.
A separation point is located under the battery.

Necessary preliminary tasks:

Remove BATTERY TRAY

Fig 1: Identifying Positive Battery Cable With Threaded Bolts

Courtesy of BMW OF NORTH AMERICA, INC.

Introductory details:

(1): Positive battery cable to be replaced with safety battery terminal, arrow marks the separation point.

(4): Vehicle positive battery cable is not replaced, arrow marks the separation point.

(7): New replacement positive battery cable, which is connected to positive battery cable (4) with threaded bolts (5, 6).

Disconnect plug (1).

Disconnect plug (2).

Disconnect plug (3).

Slacken nut (4).

Remove the positive battery cable (5) to the power distribution box from the safety battery terminal (6).

Fig 2: Identifying Positive Battery Cable And Safety Battery Terminal

Courtesy of BMW OF NORTH AMERICA, INC.

Unclip the safety battery terminal with positive battery cable (1) to below the battery holder.

Fig 3: Identifying Positive Battery Cable Clip

Courtesy of BMW OF NORTH AMERICA, INC.

Cut open heat-shrink tubing (1) and remove.

Fig 4: Identifying Heat-Shrink Tubing Cutting Position

Courtesy of BMW OF NORTH AMERICA, INC.

Disconnect positive battery cable as shown using plate shears.

Both bore holes must remain on the vehicle positive battery cable (1).

If necessary, deburr cutting edges.

Section (2) with the safety battery terminal is replaced.

If necessary, remove remnants of the heat-shrink tubing and sealing strips on the vehicle positive battery cable (1).

Fig 5: Locating Both Bore Holes On Vehicle Positive Battery Cable

Courtesy of BMW OF NORTH AMERICA, INC.

Join both cable halves.

Hold heat-shrink tubing (1) against positive battery cable.

Mark the positive battery cable on both sides as shown.

Fig 6: Identifying Mark Positive Battery Cable On Both Sides

Courtesy of BMW OF NORTH AMERICA, INC.

Place one sealing strip (1) centrally on each of the marks to the left and right of the separation point.

Push heat-shrink tubing over the positive battery cable.

Fig 7: Placing Sealing Strip On Marks

Courtesy of BMW OF NORTH AMERICA, INC.

Join repair line (2) to existing positive battery cable (1).

Tighten down nuts (3).

Tightening torque: 8 Nm.

Fig 8: Identifying Positive Battery Cable And Nuts

Courtesy of BMW OF NORTH AMERICA, INC.

Remove protective film on both sealing strips.

Position heat-shrink tubing (1) in such a way that 1 cm of sealing strip remains visible on both ends.

Fig 9: Identifying Heat-Shrink Tubing

Courtesy of BMW OF NORTH AMERICA, INC.

Shrink the heat-shrink tubing (1) with a hot air blower at 400 °C. Use a heat-shrink tubing reflector.

Fig 10: Identifying Heat-Shrink Tubing

Courtesy of BMW OF NORTH AMERICA, INC.

If necessary, renew clip (1).

Clip in complete positive battery cable and secure.

Fig 11: Identifying Positive Battery Cable Clip

Courtesy of BMW OF NORTH AMERICA, INC.

Connect the plug (1).

Connect connector (2).

Connect connector (3).

Join positive battery cable (5) to safety battery terminal (6) and tighten with nut (4).

Tightening torque: 8 Nm.

Fig 12: Identifying Positive Battery Cable And Safety Battery Terminal

Courtesy of BMW OF NORTH AMERICA, INC.