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Home >> Mini >> 2019 >> Cooper Clubman S ALL4, Standard Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 47 (Engine Electrical System - Repair - B46 & B48 Engines, Cooper S & JCW (F55, F56)) >> Safety And General Information >> (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: 

Fig 1: Butt Connector
G11774425Courtesy of BMW OF NORTH AMERICA, INC.
IMPORTANT:
  1. Identify cause of damage (e.g. sharp-edged body parts, faulty electrical loads, clamped mechanisms, corrosion caused by ingress of water, etc.).
  2. Reading out the fault memory
  3. Eliminate cause of damage.
  4. Disconnect battery negative terminal
  5. 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 (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 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.

Individual parts for wiring harness repair are available via BMW parts catalogue.

Fig 2: Vehicle Electrical System Special Tools And Individual Parts
G11774426Courtesy of BMW OF NORTH AMERICA, INC.

Choose repair kit.

Example: Repair kit, circular connector system D 2.5.

Fig 3: Repair Kit And Circular Connector System (D 2.5)
G11774427Courtesy 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 4: Crimp Connector For Selected Wire Cross-Section And Shrink-Fit Hose
G11774428Courtesy 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: 

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

Fig 5: Mark Damaged Contact With Socket Number Of Housing
G11774429Courtesy 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.
Fig 6: Checking Maximum Length Of Repair Cable
G11774430Courtesy of BMW OF NORTH AMERICA, INC.

Adhere to following procedure:

Also refer to: CUTTING/STRIPPING CABLES

Crimp butt connector on preassembled wire end.

Special tools:

See: CRIMPING ON STOP PARTS

Fig 7: Crimp Butt Connector On Preassembled Wire End
G11774431Courtesy 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
G11774432Courtesy of BMW OF NORTH AMERICA, INC.

Crimp unused wire end to butt connector.

Fig 9: Crimping Unused Wire End To Butt Connector
G11774433Courtesy of BMW OF NORTH AMERICA, INC.

Pull shrink-on sleeve over butt connector.

Fig 10: Pulling Shrink-On Sleeve Over Butt Connector
G11774434Courtesy of BMW OF NORTH AMERICA, INC.
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
G11774435Courtesy of BMW OF NORTH AMERICA, INC.
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