61 13... Butt connector for repairing a plug connection
Special tools required:
- 61 0 300
- 61 9 040 . See GENERAL ELECTRICAL SYSTEM - SPECIAL TOOLS -- CLUBMAN .
- Identify cause of damage (e.g. sharp-edged body parts, faulty electrical loads, jammed mechanisms, corrosion caused by ingress of water, etc.).
- Read out fault memory
- Eliminate cause of damage.
- Disconnect battery negative terminal
- Make sure that no safety-related system according to connection scheme (e.g. anti-lock braking system, active rear-axle kinematics, airbags, etc.) are influenced.
Otherwise replace faulty wiring harness or use repair cable
- Carry out function test and read out fault memories again
- Eliminate new faults if applicable and clear fault memories
Special tools:
- special tool 61 9 040
Choose repair kit.
Example: Repair kit, circular plug system D 2.5.
Remove following parts:
- Prepackaged end of cable with requisite wire cross-section
- Crimp connector for selected wire cross-section
- Shrink-fit hose
Open secondary lock on housing.
Mark damaged contact (4) with socket number of housing and press it out of housing using relevant special tool contained in special tool kit 61 0 300.
Refer to service information for applicable connectors in:
PLUG CONNECTION, TERMINAL, POWER DISTRIBUTION BOX
- 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.
Observe following procedure:
- Cut off wire with faulty contact at point which is easily accessible
- Strip insulation from end of wire at wiring harness end
- Cut preassembled wire end to length and strip insulation
Refer also to repair instruction:
Cutting to length and stripping insulation from cables
Crimp butt connector on preassembled wire end.
Refer to repair instructions:
Crimping on stop parts
Push shrink-fit hose (8) onto free wire end.
Crimp unused wire end to butt connector.
Pull shrink-on sleeve over butt connector.
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.