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

WARNING: This page is about a different car, the 2003 BMW X5, 2002 BMW X5, 2001 BMW X5, and 2000 BMW X5. However, it is still accessible from the selected car via links, so may be relevant.

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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