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Home >> BMW >> 2017 >> i3 Range Extender >> Repair and Diagnosis >> Accessories & Equipment >> Memory Modules >> General Electrical System - Repair >> Plug Connection, Terminal, Power Distribution Box >> 61 13... Butt connector for repairing a plug connection
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61 13... Butt connector for repairing a plug connection

Special tools required: 

IMPORTANT:
  1. Identify cause of damage (e.g. sharp-edged body components, faulty electrical loads, jammed mechanisms, corrosion caused by ingress of water, etc.).
  2. Read out fault memory
  3. Eliminate cause of damage.
  4. Disconnect battery negative terminal
  5. 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.
  6. Carry out function test and read out fault memories again
  7. 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 via BMW parts catalogue.
Fig 1: Identifying Special Tools Kit
G04727459Courtesy of BMW OF NORTH AMERICA, INC.

Choose repair kit.

Example: Repair kit, circular connector system D 2.5.

Fig 2: Identifying Circular Connector And Repair Kit
G04727460Courtesy of BMW OF NORTH AMERICA, INC.

Remove following parts:

  1. Pre-packaged end of cable with requisite wire cross-section
  2. Crimp connector for selected wire cross-section
  3. Shrink-fit hose
Fig 3: Identifying Cable End, Crimp Connector And Shrink-Fit Hose
G04727461Courtesy 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 Cable Damage Contact
G04727462Courtesy 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:

Fig 5: Identifying Wire Stripper
G04727463Courtesy of BMW OF NORTH AMERICA, INC.

Refer also to repair instruction: 

CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES 

Crimp butt connector on preassembled wire end.

Special tools:

See repair instructions: 

CRIMPING ON STOP PARTS 

Fig 6: Identifying Butt Connector Crimp On Preassembled Wire End
G04727464Courtesy of BMW OF NORTH AMERICA, INC.

Push shrink-fit hose (8) onto free wire end.

Fig 7: Identifying Free Wire End Shrink-Fit Hose
G04727465Courtesy of BMW OF NORTH AMERICA, INC.

Crimp unused wire end to butt connector.

Fig 8: Identifying Crimp Unused Wire End To Butt Connector
G04727466Courtesy of BMW OF NORTH AMERICA, INC.

Pull shrink-on sleeve over butt connector.

Fig 9: Pulling Shrink-On Sleeve Over Butt Connector
G04727467Courtesy of BMW OF NORTH AMERICA, INC.
IMPORTANT: Do not burn shrink-on sleeve.

With hot air blower, shrink the shrink-on sleeve on both sides (9) of shrink-fit hose until glue emerges uniformly all round.

Insert contact in housing.

Close secondary lock on housing.

Fig 10: Identifying Butt Connector Shrink-On Sleeve
G04727468Courtesy of BMW OF NORTH AMERICA, INC.
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