61 11... Installing the repair cable for the positive battery cable of the power distribution box

Read and comply with NOTES ON HANDLING WIRING HARNESSES AND WIRING !

Read and comply with NOTES ON CRIMPING STOPS !

Necessary preliminary work: 

Remove GLOVE BOX

Remove JUNCTION BOX 

Work is shown on the E90 by way of example.

There may be differences in detail in the case of other vehicle types and equipment specifications.

Disconnect plug connection (1).

Release the wiring harness mounting (2) from the power distribution box (6).

Release screws (3).

Fig 1: Identifying Fuse Box Interior And Fuse Box Interior Holder

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Disconnect the positive battery cable (2).

Extra plug connections (1) on the back of the power distribution box (3) must not be detached.

Fig 2: Identifying Fuse Box Interior And Plug Connections

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Open retaining straps (1). Pull out positive battery cable (2) as far as possible.

Fig 3: Identifying Battery Cable And Retaining Straps

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Pre-drill both bridges (2) of the power distribution box (1) at the area marked with an arrow with a 2 mm drill. Then drill through with a 5 mm drill.

Fig 4: Identifying Power Distribution Box And Bridges

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1. Measure a 15 cm length as shown and mark on the positive battery cable (1).
2. Cut off the positive battery cable (1) at the marked location with special tool 2 337 974 (cable shears).
3. At the cut-off end of the positive battery cable (1), measure and mark 2 cm.
4. Carefully strip insulation off of the positive battery cable (1) at the marked location with special tool 2 337 974 (cable shears).

Fig 5: Identifying Measuring, Cutting, And Stripping Points

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1. Mount the heat-shrink tubing (1) on the repair positive battery cable. Insert the repair positive battery cable as shown in the special tool 2 339 646.

   (Pliers 2 339 646, die plate 2 339 647)

2. Position the contact (2) as shown.
3. Close special tool. Turn the screw plug (3) anti-clockwise and move it to the position shown.

Fig 6: Identifying Heat Shrink Tubing, Contact, And Special Tool 2 339 646

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Crimp the vehicle-side positive battery cable (2) and the repair positive battery cable (1) using the special tool 2 339 646.

(Pliers 2 339 646, die plate 2 339 647)

After crimping, copper wires of the vehicle-side positive battery cable (2) must be visible in the opening (3).

Fig 7: Crimping Vehicle-Side Positive Battery Cable And Repair Positive Battery Cable Using Special Tool 2 339 646

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1. Centrally measure and mark distance = 10 cm as shown.
2. Position the heat-shrink tubing (2) over the crimping location so that mark (3) is must barely visible.
3. Shrink the heat-shrink tubing (2) with a hot air blower 0 444 131 at 400 °C.
4. After shrinking, adhesive (4) must emerge from both sides of the heat-shrink tubing (2).

Fig 8: Installing Heat Shrink Tubing Over Crimping Location

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Connect the repair positive battery cable (3) to the power distribution box (1) by pushing down all the way.

Tighten screw (2). Tightening torque: 1, 5 Nm

While tightening the bolt (2), continue pushing down the contact. 

Fasten the repair positive battery cable (3) on the power distribution box (1) at the location indicated by the arrow using a cable strap (4).

Fig 9: Identifying Repair Positive Battery Cable, Power Distribution Box, Screw, And Cable Strap

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Mount the cap (1) flush.

Fig 10: Identifying Cap

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Fasten the positive battery cable (1) at locations (2).

Fig 11: Fastening Positive Battery Cable

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