12 42 540 Replacing safety battery terminal (SBK): Installation:

Remove faulty fuses and carry out troubleshooting.

Fig 1: Removing Faulty Fuses And Carrying Out Troubleshooting

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CAUTION: Pay attention to interface.
The repair cable is always a standard length.
The heavy-current connector of the repair cable has a larger diameter than the battery positive lead.

Lay repair cable parallel to battery positive lead.

Mark interface of battery positive lead at end of repair cable.

Fig 2: Laying Repair Cable Parallel To Battery Positive Lead

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Release cable ties (1).

Disconnect plug connection (2).

Fig 3: Releasing Cable Ties

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CAUTION: Do not use bolt cutters or similar tools to cut through the cable.

A cable end that has been squashed flat will no longer fit into the clamping sleeve.

Saw through battery positive cable at marked point with an iron saw.

Fig 4: Identifying Pipe

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Strip insulation - length (A) - from cable end.

Distance (A) = 15 mm.

Fig 5: Measuring Distance Of Pipe

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Push heavy-current connector (1) over stripped cable end and screw into position.

Fig 6: Pushing Heavy-Current Connector Over Stripped Cable End And Screw Into Position

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Push shrink-fit hose (3) over repair cable.

Screw threaded sleeve (1) of repair cable (2) to heavy-current connector.

Fig 7: Screwing Threaded Sleeve Of Repair Cable To Heavy-Current Connector

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Push shrink-fit hose (1) over connecting point and shrink on with a hot-air blower (2).

Fig 8: Pushing Shrink-Fit Hose

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NOTE: Heat up shrink-fit hose until it has settled completely around the connection point.

Fig 9: Heating Up Shrink-Fit Hose

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When laying the repaired battery positive cable, observe the following:

The shrink-fit hose must not be scuffed during any movement.
The repair cable must not cause any disturbing noises during driving operation.
NOTE: Offsetting cutting line by approx. 10 cm produces excess length of battery positive lead (1).

Lay battery positive lead (1) without kinks or abrasions.

(Shown on E46 touring.)

Fig 10: Identifying Offsetting Cutting Line
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