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Home >> BMW >> 2013 >> 335is 2D Convertible, Standard Trans >> Repair and Diagnosis >> Accessories & Equipment >> Memory Modules >> General Electrical System - Repair - E93 >> Plug Connection, Terminal, Power Distribution Box >> 61 13... Butt connector for repairing a plug connection

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

Special tools required: 

IMPORTANT:
  1. Identify cause of damage (e.g. sharp-edged body components, 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 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 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: 

Choose repair kit.

Example: Repair kit, circular connector system D 2.5.

Fig 2: Identifying Repair Kit
G09863230Courtesy 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 Shrink-Fit Hose, Crimp Connector, And Wire Cross-Section With Cable Ends
    G09863231Courtesy 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: 

OPENING PLUG HOUSINGS AND REMOVING CONTACTS OF DIFFERENT PLUG SYSTEMS 

Fig 4: Identifying Contact
G09863232Courtesy 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 Butt Connector And Wire End
G09863234Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 7: Pushing Shrink-Fit Hose Onto Free Wire End
G09863235Courtesy of BMW OF NORTH AMERICA, INC.

Crimp unused wire end to butt connector.

Fig 8: Crimping Unused Wire End To Butt Connector
G09863236Courtesy of BMW OF NORTH AMERICA, INC.

Pull shrink-fit hose over butt connector.

Fig 9: Pulling Shrink-Fit Hose Over Butt Connector
G09863237Courtesy of BMW OF NORTH AMERICA, INC.
IMPORTANT: Do not burn shrink-on sleeve.

With hot air blower, shrink the shrink-fit hose 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-Fit Hose On Both Sides
G09863238Courtesy of BMW OF NORTH AMERICA, INC.
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