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

WARNING: This page is about a different car, the 2011 BMW X6 and 2010 BMW X6. However, it is still accessible from the selected car via links, so may be relevant.

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 (sourcing reference: BMW Parts Department)
  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 through BMW Parts Department.

Special tools: 

Choose repair kit.

Example: Repair kit, circular connector system D 2.5.

Fig 2: Example Of Repair Kit, Circular Connector System (D 2.5)
G08573740Courtesy 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 Pre-Packaged End, Crimp Connector And Shrink-Fit Hose
    G08573741Courtesy 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 

Opening plug housings and removing contacts of different plug systems

Fig 4: Identifying Damaged Contact Of Housing
G08573742Courtesy 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 Harness Wire Cutting Tool
G08573743Courtesy 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.

See Repair Instructions 

CRIMPING ON STOP PARTS 

Fig 6: Stripping Cable Insulation
G08573744Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 7: Identifying Shrink-Fit Hose
G08573745Courtesy of BMW OF NORTH AMERICA, INC.

Crimp unused wire end to butt connector.

Fig 8: Crimping Unused Wire End To Butt Connector
G08573746Courtesy of BMW OF NORTH AMERICA, INC.

Pull shrink-on sleeve over butt connector.

Fig 9: Pulling Shrink-On Sleeve Over Butt Connector
G08573747Courtesy 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 Shrink-On Sleeve Both Sides
G08573748Courtesy of BMW OF NORTH AMERICA, INC.
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