Butt connector for repairing a plug connection (all 7' series models 2016-2022)

Special tools required: 

• 61 0 300 
• 61 4 340 
• 61 0 240 

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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

• Refer to Service Information:

  Recoding of spare parts (housings and contacts) from "Repair set 4 for vehicle electrical system" 

  • Situation: 
    • The individual special tools numbers from "Repair set 4 for vehicle electrical system" are no longer available from Cartool.
    • With immediate effect, all spare parts from "Repair set 4 for vehicle electrical system" (e.g. repair sets "A" to "N" with special tools number 61 9 050 and 61 9 06x) can be ordered from the BMW Parts Service.
    • Proceed as follows to ensure correct assignment or recoding of the special tools number concerned to the BMW part number .
  • Procedure: 
    • Orders for spare parts from "Repair set 4 for vehicle electrical system" should only be placed with the BMW Parts Service.

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Choose repair kit.

Example: Repair kit, circular connector system D 2.5.

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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

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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 

UNLOCKING AND DISCONNECTING DIFFERENT PLUG CONNECTIONS , or UNLOCKING AND DISCONNECTING VARIOUS PLUG CONNECTIONS IN ELECTRICAL AND HYBRID VEHICLES  .

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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 preassembled wire end to length and strip off insulation

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Refer also to repair instruction: 

Cutting to length and stripping off insulation from cables

Crimp butt connector on preassembled 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 STOPPING PARTS .

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

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Crimp unused wire end to butt connector.

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Pull shrink-on sleeve over butt connector.

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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.