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Home >> Mini >> 2014 >> Cooper Base, 2D Convertible, Standard Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 1827 (General Electrical System - Repair) >> 13 Plug Connection, Terminals, Fuse Box >> 61 13 Butt Connector For Repairing A Plug Connection
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61 13 Butt Connector For Repairing A Plug Connection

WARNING: This page is about a different car, the 2007 BMW 550i and 2006 BMW 550i. 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 parts, 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 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.
  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 Service.

Special tools: 

Choose repair kit.

Example: Repair kit, circular plug system D 2.5.

Fig 1: Identifying Special Tool Repair Kit
G04957408Courtesy of BMW OF NORTH AMERICA, INC.
Fig 2: Identifying Repair Kit, Circular Plug System D 2.5.
G04957409Courtesy of BMW OF NORTH AMERICA, INC.

Remove following parts:

  1. Prepackaged end of cable with requisite wire cross-section
  2. Crimp connector for selected wire cross-section
  3. Shrink-fit hose
Fig 3: Identifying Shrink-Fit Hose, And Crimp Connector For Selected Wire Cross-Section
G04957410Courtesy 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  .

Refer to repair instructions: 

OPENING PLUG HOUSINGS AND REMOVING CONTACTS  of different plug systems

Fig 4: Identifying Damaged Contact
G04957411Courtesy 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:

Refer also to repair instruction: 

CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES 

Fig 5: Identifying Wire With Faulty Contact At Point
G04957412Courtesy of BMW OF NORTH AMERICA, INC.

Crimp butt connector on preassembled wire end.

Refer to repair instructions: 

CRIMPING ON STOP PARTS 

Fig 6: Identifying Crimp Butt Connector On Preassembled Wire End
G04957413Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 7: Identifying Shrink-Fit Hose Onto Free Wire End
G04957414Courtesy of BMW OF NORTH AMERICA, INC.

Crimp unused wire end to butt connector.

Fig 8: Identifying Crimp Unused Wire End To Butt Connector
G04957415Courtesy of BMW OF NORTH AMERICA, INC.

Pull shrink-on sleeve over butt connector.

Fig 9: Identifying Shrink-On Sleeve Over Butt Connector
G04957416Courtesy 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 On Both Sides
G04957417Courtesy of BMW OF NORTH AMERICA, INC.
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