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Home >> Mini >> 2010 >> Cooper S, 2D Hatchback, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 3796 (General Electrical System - Repair - F13) >> Plug Connection, Terminal, Power Distribution Box >> 61 13... Butt connector for repairing a plug connection

61 13... Butt connector for repairing a plug connection

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Special tools required: 

IMPORTANT:
  1. Identify cause of damage (e.g. sharp-edged body components, faulty electrical loads, jammed mechanisms, corrosion caused by ingress of water, etc.).
  2. Read out fault memory
  3. Eliminate cause of damage.
  4. Disconnect battery negative terminal
  5. Make sure that no safety-related system according to circuit diagram (e.g. antilock braking system, active rear-axle kinematics, airbags, etc.) are influenced. 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
NOTE: The repair range IV for vehicle electrical system contained the required special tools and individual parts for retrofitting and repair work with the aid of fan connectors.

The case can no longer be ordered. Order individual parts for wiring harness repair through BMW Parts Department.

Fig 1: Identifying Repair Kit
G10063945Courtesy of BMW OF NORTH AMERICA, INC.

Choose repair kit.

Example: Repair kit, circular connector system D 2.5.

Fig 2: Identifying Repair Parts
G10063946Courtesy 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
    Fig 3: Identifying Cable End, Crimp Connector, And Shrink-Fit Hose
    G10063947Courtesy 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: OPENING CONTACTS AND LOCKS OF DIFFERENT CONNECTOR SYSTEMS .

.

Fig 4: Identifying Damaged Contact
G10063948Courtesy of BMW OF NORTH AMERICA, INC.
IMPORTANT:
  • 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:

Refer also to repair instruction: 

CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES 

Crimp butt connector on preassembled wire end.

Special tools:

See repair instructions: CRIMPING ON STOP PARTS .

Fig 6: Crimping Butt Connector On Preassembled Wire End
G10063950Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 7: Pushing Shrink-Fit Hose Onto Free Wire End
G10063951Courtesy of BMW OF NORTH AMERICA, INC.

Crimp unused wire end to butt connector.

Fig 8: Crimping Unused Wire End To Butt Connector
G10063952Courtesy of BMW OF NORTH AMERICA, INC.

Pull shrink-on sleeve over butt connector.

Fig 9: Pulling Shrink-On Sleeve Over Butt Connector
G10063953Courtesy of BMW OF NORTH AMERICA, INC.
IMPORTANT: Do not burn 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.

Fig 10: Identifying Shrink-On Sleeve Sides
G10063954Courtesy of BMW OF NORTH AMERICA, INC.
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