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

WARNING: This page is about a different car, the 2013 BMW X5 M, 2012 BMW X5 M, 2011 BMW X5 M, and 2010 BMW X5 M. 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: Identifying Repair Kit
G08530313Courtesy 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, Connector And Shrink-Fit Hose
    G08530314Courtesy 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 Mark On Contact
G08530315Courtesy 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.
Fig 5: Identifying Crimp Tool
G08530316Courtesy of BMW OF NORTH AMERICA, INC.

Adhere to following procedure:

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: Identifying Crimp Butt Connector On Preassembled Wire End
G08530317Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 7: Identifying Shrink-Fit Hose
G08530318Courtesy of BMW OF NORTH AMERICA, INC.

Crimp unused wire end to butt connector.

Fig 8: Identifying Unused Wire End And Butt Connector
G08530319Courtesy of BMW OF NORTH AMERICA, INC.

Pull shrink-on sleeve over butt connector.

Fig 9: Identifying Shrink-On Sleeve Over Butt Connector
G08530320Courtesy 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 Shrink-On Sleeve Ends
G08530321Courtesy of BMW OF NORTH AMERICA, INC.
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