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

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.

Fig 1: Identifying Individual Parts For Repairing Wiring Harness
G08420052Courtesy of BMW OF NORTH AMERICA, INC.

Choose repair kit.

Example: Repair kit, circular connector system D 2.5.

Fig 2: Identifying Repair Kit
G08420053Courtesy 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 Pre-Packaged End Of Cable With Requisite Wire Cross-Section, Crimp Connector For Selected Wire Cross-Section And Shrink-Fit Hose
    G08420054Courtesy 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 

NOTES FOR OPENING CONTACTS AND LOCKS  of different plug contact systems.

Fig 4: Identifying Damaged Contact Removed Out Of Housing
G08420055Courtesy 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 Wire Cutter
G08420056Courtesy 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.

Special tools:

See repair instructions 

CRIMPING ON STOP PARTS

Fig 6: Identifying Crimping Tool
G08420057Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 7: Identifying Shrink-Fit Hose
G08420058Courtesy of BMW OF NORTH AMERICA, INC.

Crimp unused wire end to butt connector.

Fig 8: Identifying Unused Wire End Crimped To Butt Connector
G08420059Courtesy of BMW OF NORTH AMERICA, INC.

Pull shrink-on sleeve over butt connector.

Fig 9: Identifying Shrink-On Sleeve Over Butt Connector
G08420060Courtesy 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
G08420061Courtesy of BMW OF NORTH AMERICA, INC.
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