LEMON Manuals: Even more car manuals for everyone
Home >> Mini >> 2012 >> Cooper Base, 2D Convertible, Automatic Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 2419 (General Electrical System - Repair (E88)) >> Plug Connections, Terminals, Power Distribution Box >> 61 13... Butt Connector For Repairing A Plug Connection >> Special Tools Required

Special Tools Required

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2013 BMW 128i, 2012 BMW 128i, 2011 BMW 128i, 2010 BMW 135i, and 2010 BMW 128i. However, it is still accessible from the selected car via links, so may be relevant.
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 connection scheme (e.g. anti-lock 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. Order individual parts for wiring harness repair through BMW Parts Service.

Special tools: 

Example: Repair kit, circular plug system D 2.5.

Fig 2: Repair Kit
G04776133Courtesy of BMW OF NORTH AMERICA, INC.

Remove following parts:

  1. Prepackaged 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
    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 relevant 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 Socket
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.

Observe following procedure:

Refer also to repair instruction: 

CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES 

Crimp butt connector on preassembled wire end.

Fig 6: Cutting Length & Stripping Insulation From Cables
G04727464Courtesy 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
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: Inserting Contact In Housing
G04727468Courtesy of BMW OF NORTH AMERICA, INC.
scientia non olet · About LEMON Manuals