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

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2019 MINI Cooper, 2018 MINI Cooper, 2017 MINI Cooper, 2016 MINI Cooper, and 2015 MINI Cooper. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

Fig 1: Butt Connector

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT:

Identify cause of damage (e.g. sharp-edged body parts, faulty electrical loads, clamped mechanisms, corrosion caused by ingress of water, etc.).
Reading out the fault memory
Eliminate cause of damage.
Disconnect battery negative terminal
Make sure that, according to circuit diagram, no safety-related systems (e.g. ABS, active rear-axle kinematics, airbags, etc.) are affected. Otherwise replace faulty wiring harness or use repair cable (available via BMW/MINI parts catalogue)
Carry out function test and read out fault memories again
Eliminate new faults if applicable and clear fault memories

NOTE: The repair product range IV for vehicle electrical system contains 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 via BMW/MINI parts catalogue.

Fig 2: Special Tools And Individual Parts

Courtesy of BMW OF NORTH AMERICA, INC.

Choose repair kit.

Example: Repair kit, circular connector system D 2.5.

Fig 3: Example Of Repair Kit, Circular Connector 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 4: Crimp Connector For Selected Wire Cross-Section 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 ).

See repair instructions:

NOTES FOR OPENING CONTACTS AND LOCKS OF DIFFERENT PLUG CONTACT SYSTEMS .

Fig 5: Marking Damaged Contact With Socket Number Of Housing

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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 6: Wire Stripper

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Adhere to following procedure:

Cut off wire with faulty contact at point which is easily accessible
Strip off insulation from end of wire at wiring harness end
Cut preassembled wire end to length and strip off insulation

Refer also to repair instruction:

CUTTING OFF/STRIPPING INSULATION/CUTTING TO LENGTH

Crimp butt connector on preassembled wire end.

Special tools:

61 4 340 (0.35 - 2.5 sq mm)
61 0 240 (4.0 - 6.0 sq mm)

See repair instructions:

CRIMPING ON STOP PARTS

Fig 7: Butt Connector

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 8: Pushing Shrink-Fit Hose Onto Free Wire End

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Crimp unused wire end to butt connector.

Fig 9: Crimping Unused Wire End To Butt Connector

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Pull shrink-on sleeve over butt connector.

Fig 10: Pulling Shrink-On Sleeve Over Butt Connector

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IMPORTANT: Do not combustion 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 11: Shrink-On Sleeve On Both Sides Of Shrink-Fit Hose

Courtesy of BMW OF NORTH AMERICA, INC.