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

Special tools required:

IMPORTANT:

Identify cause of damage (e.g. sharp-edged body components, 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 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)
Carry out function test and read out fault memories again
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.

Special tools :

Special tool 61 9 040

Fig 1: Identifying Special Tools

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Choose repair kit.

Example: Repair kit, circular connector system D 2.5.

Fig 2: Identifying Circular Plug System D 2.5

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Remove following parts:

Pre-packaged end of cable with requisite wire cross-section
Crimp connector for selected wire cross-section
Shrink-fit hose

Fig 3: Identifying Cable With Requisite Wire Cross-Section, Crimp Connector And Shrink-Fit Hose
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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 ).

OPENING PLUG HOUSINGS AND REMOVING CONTACTS of different plug systems

Fig 4: Identifying Damage Cable With Socket Number
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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.
Fig 5: Identifying Crimp Tool
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Adhere to 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 pre-assembled wire end to length and strip insulation
Refer also to instructions for CUTTING/STRIPPING CABLES .

Crimp butt connector on pre-assembled wire end.

Refer to CRIMPING ON STOP PARTS

Fig 6: Identifying Crimp Butt Connector On Pre-assembled Wire End
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Push shrink-fit hose (8) onto free wire end.

Fig 7: Identifying Shrink-Fit Hose On Free Wire End
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Crimp unused wire end to butt connector.

Fig 8: Crimping Of Unused Wire End To Butt Connector
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Pull shrink-on sleeve over butt connector.

Fig 9: Identifying Shrink-On Sleeve And Butt Connector
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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 Shrink-On Sleeve Ends
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