61 11... Installing the repair cable for EME positive battery cable
Special tools required:
The repair instructions describe installation of the repair cable for the EME positive battery terminal.
(part number 8 646 412)
Read and comply with notes on handling wiring harnesses and wiring!
READ AND COMPLY WITH NOTES ON CRIMPING STOPS!
Necessary preliminary work:
DISCONNECT NEGATIVE BATTERY LEAD
REMOVE REAR UNDERBODY PROTECTION
Work is shown on the F10 by way of example.
There may be differences in detail in the case of other vehicles.
Removal:
Slacken nut (1).
Remove positive battery cable (2).
Repair of the EME positive battery cable:
Measure off 17 cm as shown and mark (2).
Cut off the positive battery cable (1) at the marked location (2) with special tool 2 337 994.
7 cm after the separation point (2), mark (3) corrugated tubing (4).
Do not cut positive battery cable (1) again .
Do not damage positive battery cable (1) insulation .
At the marked point (3), carefully cut off only the external corrugated tubing (4) with special tool 2 337 994.
Remove cut-off corrugated tubing (4) from positive battery cable (1).
Measure off and mark 2 cm at the separation point of the vehicle-side positive battery cable and at the end of the repair cable (1).
Carefully strip insulation from both cables at marked locations using special tool 2 337 994.
Do not damage the strands during stripping!
Push sleeve (2) onto repair cable (1).
Position sleeve (2) in special tool 2 339 646 as shown.
Close special tool 2 339 646 . To do this, turn screw (3) in counterclockwise direction.
Crimp sleeve (2) onto repair cable (1) using special tool 2 339 646 .
After crimping, copper wires of repair cable (1) must be visible in the center opening of the sleeve (2)!
(Pliers 2 339 646 , die plate 2 339 647 )
Pliers 2 339 646 must be operated approx. 20 times during the crimping process.
Crimping process is complete when pliers 2 339 646 automatically open.
Push heat-shrink tubing onto repair cable (1).
Position repair cable (1) in special tool 2 339 646 as shown.
Push sleeve onto vehicle-side positive battery cable.
Crimp repair cable and vehicle-side positive battery cable together using special tool 2 339 646 .
After crimping, copper wires of the vehicle-side positive battery cable must be visible in the center opening of the sleeve.
(Pliers 2 339 646 , die plate 2 339 647 )
Pliers 2 339 646 must be operated approx. 20 times during the crimping process.
Crimping process is complete when pliers 2 339 646 automatically open.
Centrally measure and mark distance (A) = 10 cm as shown.
Centrally stick the sealing tape (1) contained in the repair kit onto the markings.
Centrally position the heat-shrink tubing over the crimp location so that the sealing tape (1) protrudes uniformly from the heat-shrink tubing on the right and left.
Shrink the heat-shrink tubing with hot air blower 0 444 131. Use a heat-shrink tubing reflector.
(Heat shrink temperature 400 °C )
Installation:
Hold down washer (2) .
Install washer (2) from repair kit!
Mount contact (3) of repair cable (1) and secure by means of nut.
Tightening torque: 15 Nm
Example figure.
- Completely fill chamber (1) with contact protection grease.
(part number 2 295 229)
- Mount end cover (2). Wipe off excess grease.