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Home >> BMW >> 2009 >> 335d >> Repair and Diagnosis (Single Page) >> Accessories & Equipment >> Memory Modules >> General Electrical System - Repair >> Plug Connection, Terminal, Fuse Box >> 6113... Butt connector for repairing a plug connection >> Notes

6113... Butt connector for repairing a plug connection: Notes

IMPORTANT:
  1. Identify cause of damage (e.g. sharp-edged body parts, faulty electrical loads, jammed mechanisms, corrosion caused by ingress of water, etc.).
  2. Read out fault memory
  3. Eliminate cause of damage.
  4. Disconnect battery negative terminal
  5. 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 Service)
  6. Carry out function test and read out fault memories again
  7. 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.

Special tools: 

Choose repair kit.

Example: Repair kit, circular plug system D 2.5.

Fig 2: Identifying Repair Kit, Circular Plug System D 2.5
G04727460Courtesy 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 3: Identifying Cable With Requisite Wire Cross-Section, Crimp Connector And Shrink-Fit Hose
    G04727461Courtesy 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 kit 61 0 300 .

See repair instructions 

OPENING PLUG HOUSINGS AND REMOVING CONTACTS  of different plug systems

Fig 4: Identifying Damaged Contact
G04727462Courtesy 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.

Adhere to following procedure:

Refer also to repair instruction: 

CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES 

Crimp butt connector on preassembled wire end.

See repair instructions 

CRIMPING ON STOP PARTS 

Fig 6: Identifying Crimp Butt Connector On Preassembled Wire End
G04727464Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 7: Identifying Shrink-Fit Hose On Free Wire End
G04727465Courtesy of BMW OF NORTH AMERICA, INC.

Crimp unused wire end to butt connector.

Fig 8: Crimping Unused Wire End To Butt Connector
G04727466Courtesy of BMW OF NORTH AMERICA, INC.

Pull shrink-on sleeve over butt connector.

Fig 9: Pulling Shrink-On Sleeve Over Butt Connector
G04727467Courtesy of BMW OF NORTH AMERICA, INC.
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: Shrinking Shrink-On Sleeve On Both Sides Of Shrink-Fit Hose
G04727468Courtesy of BMW OF NORTH AMERICA, INC.
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