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

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

Remove faulty fuses and carry out troubleshooting.

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.
In some Series (e.g. E46 touring), the heavy-current connector of the repair cable can lead to installation problems.
This is the case when the interface is in the area of the close-fitting trim panels.
Find matching interface (e.g. approx. 10 cm behind rear seat backrest in E46 touring).

Lay repair cable parallel to battery positive lead.

Mark interface of battery positive lead at end of repair cable.

Fig 1: Marking Interface

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Courtesy of BMW OF NORTH AMERICA, INC.

Release cable ties (1).

Disconnect plug connection (2).

Fig 2: Disconnecting Plug Connection

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Courtesy of BMW OF NORTH AMERICA, INC.

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 3: Cutting Cable

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Courtesy of BMW OF NORTH AMERICA, INC.

Strip insulation - length (A) -from cable end.

Distance (A) = 15 mm.

Fig 4: Stripping Insulation

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Courtesy of BMW OF NORTH AMERICA, INC.

Push heavy-current connector (1) over stripped cable end and screw into position.

Fig 5: Installing Heavy-Current Connector

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Courtesy of BMW OF NORTH AMERICA, INC.

Push shrink-fit hose (3) over repair cable.

Screw threaded sleeve (1) of repair cable (2) to heavy-current connector.

Fig 6: Pushing Shrink-Fit Hose Over Repair Cable

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Courtesy of BMW OF NORTH AMERICA, INC.

Push shrink-fit hose (1) over connecting point and shrink on with a hot-air blower (2).

Fig 7: Pushing Shrink-Fit Hose Over Connecting Point

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Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Heat up shrink-fit hose until it has settled completely around the connection point.

Fig 8: View Of Shrink-Fit Hose

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Courtesy of BMW OF NORTH AMERICA, INC.

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 9: Laying Battery Positive Lead

G03191061

Courtesy of BMW OF NORTH AMERICA, INC.