Butt connector for repairing a plug connection

Special tools required: 

• 61 0 300
• 61 4 340
• 61 0 240

Courtesy of BMW OF NORTH AMERICA, INC.

Attention! 

1. Identify cause of damage (e.g. sharp-edged body parts, faulty electrical loads, clamped mechanisms, corrosion caused by ingress of water, etc.).
2. Reading out the fault memory
3. Eliminate cause of damage.
4. Disconnect battery negative terminal
5. Make sure that, according to circuit diagram, no safety-related systems (e.g. ABS, active rear-axle kinematics, airbags, etc.) are affected. 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

Courtesy of BMW OF NORTH AMERICA, INC.

Choose repair kit.

Example: Repair kit, circular connector system D 2.5.

Courtesy 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

Courtesy 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 .

Courtesy of BMW OF NORTH AMERICA, INC.

Attention! 

• 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.

Adhere to following procedure:

• Cut off wire with faulty contact at point which is easily accessible
• Strip off insulation from end of wire at wiring harness end
• Cut pre-assemble wire end to length and strip off insulation

Refer also to repair instruction: 

CUTTING TO LENGTH AND STRIPPING OFF INSULATION FROM CABLES .

Courtesy of BMW OF NORTH AMERICA, INC.

Crimp butt connector on pre-assemble wire end.

Special tools:

• 61 4 340 (0.35 - 2.5 mm² )
• 61 0 240 (4.0 - 6.0 mm² )

See repair instructions: 

CRIMPING ON STOP PARTS .

Courtesy of BMW OF NORTH AMERICA, INC.

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

Courtesy of BMW OF NORTH AMERICA, INC.

Crimp unused wire end to butt connector.

Courtesy of BMW OF NORTH AMERICA, INC.

Pull shrink-on sleeve over butt connector.

Courtesy of BMW OF NORTH AMERICA, INC.

Attention! 

Do not combustion 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.

Courtesy of BMW OF NORTH AMERICA, INC.