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Home >> BMW >> 2008 >> 323i Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 665 (General Electrical System - Repair - E92/E93) >> Plug Connection, Terminals, Fuse Box >> 61 13 Butt connector for repairing a plug connection

61 13 Butt connector for repairing a plug connection

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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.

Special tools: 

Choose repair kit.

Example: Repair kit, circular plug system D 2.5.

Fig 1: Identifying Repair Kit
G04753249Courtesy of BMW OF NORTH AMERICA, INC.
Fig 2: Identifying Circular Plug System
G04753250Courtesy 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 Prepackaged End Of Cable, Crimp Connector And Shrink-Fit Hose
    G04753251Courtesy 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
G04753252Courtesy 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 Special Tool
    G04753253Courtesy of BMW OF NORTH AMERICA, INC.

Observe following procedure:

Refer also to repair instruction: 

Cutting To Length And Stripping Insulation From Cables  

Crimp butt connector on pre-assembled wire end.

Refer to repair instructions: 

Crimping On Stop Parts  

Fig 6: Identifying Crimp Butt Connector On Pre-assembled Wire End
G04753254Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 7: Pushing Shrink-Fit Hose Onto Free Wire End
G04753255Courtesy of BMW OF NORTH AMERICA, INC.

Crimp unused wire end to butt connector.

Fig 8: Crimping Wire End To Butt Connector
G04753256Courtesy of BMW OF NORTH AMERICA, INC.

Pull shrink-on sleeve over butt connector.

Fig 9: Pulling Shrink-On Sleeve Over Butt Connector
G04753257Courtesy 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 Of Shrink-Fit Hose
G04753258Courtesy of BMW OF NORTH AMERICA, INC.
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