61 13 Butt Connector For Repairing A Plug Connection

WARNING: This page is about a different car, the 2008 BMW Alpina and 2007 BMW Alpina. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

61 0 300
61 9 040

IMPORTANT:

Identify cause of damage (e.g. sharp-edged body parts, 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 connection scheme (e.g. anti-lock braking system, active rear-axle kinematics, airbags, etc.) are influenced. Otherwise replace faulty wiring harness or use repair cable (sourcing reference: BMW Parts Service)
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 Service.

Special tools:

Special tool 61 9 040

Choose repair kit.

Example: Repair kit, circular plug system D 2.5.

Fig 1: Identifying Repair Kit

Courtesy of BMW OF NORTH AMERICA, INC.

Fig 2: Identifying Circular Plug System

Courtesy of BMW OF NORTH AMERICA, INC.

Remove following parts:

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

Fig 3: Identifying 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 relevant special tool contained in special tool kit 61 0 300 .

Opening plug housings and removing contacts of different plug systems. See 61 13 OPENING PLUG HOUSINGS AND REMOVING CONTACTS OF DIFFERENT PLUG SYSTEMS .

Fig 4: Identifying Mark Damaged Contact And 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.

Observe following procedure:

Cut off wire with faulty contact at point which is easily accessible.
Strip wiring-harness wire end (6).
Cut preassembled wire end (7) to length and strip insulation.

Fig 5: Identifying Special Tool
Courtesy of BMW OF NORTH AMERICA, INC.