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Home >> Mini >> 2009 >> Cooper Base, 2D Convertible, Standard >> Repair and Diagnosis >> Accessories & Equipment >> Memory Modules >> General Electrical System - Repair - Convertible (R57) >> Plug Connections, Terminals, Power Distribution Box >> 61 13... Butt connector for repairing a plug connection

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

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
  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 Service.

Fig 1: Identifying Special Tool For Repairing Vehicle Electrical System
G04727459Courtesy of BMW OF NORTH AMERICA, INC.

Choose repair kit.

Example: Repair kit, circular plug system D 2.5.

Fig 2: Identifying 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 Crimp Connector For Selected Wire Cross-Section And Shrink-Fit Hose
G06213312Courtesy 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 .

Refer to applicable service information for PLUG CONNECTIONS, TERMINALS, POWER DISTRIBUTION BOX .

Fig 4: Identifying Damaged Contact
G06917800Courtesy 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:

Fig 5: Identifying Crimp Tool
G04727463Courtesy of BMW OF NORTH AMERICA, INC.

Refer also to: 

CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES 

Crimp butt connector on preassembled wire end.

Special tools:

Refer to 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: Identifying Unused Wire End And Butt Connector Connection
G06917804Courtesy of BMW OF NORTH AMERICA, INC.

Pull shrink-on sleeve over butt connector.

Fig 9: Identifying Shrink-On Sleeve On 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: Identifying Shrink-On Sleeve Position
G04789335Courtesy of BMW OF NORTH AMERICA, INC.
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