BMW X5: Butt Connector For Repairing A Plug Connection

Special tools required:

• 61 0 300
• 61 9 040

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:

• Special tool 61 9 040

Fig. 33: Identifying BMW Special Tool Kit

Choose repair kit.

Example: Repair kit, circular plug system D 2.5.

Fig. 34: Identifying Repair Kit

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. 35: Identifying Cable, Connector And Shrink-Fit Hose

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.

Fig. 36: Removing Damaged Contact

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.

Fig. 37: Identifying Cutting Tool

Observe following procedure:

• Cut off wire with faulty contact at point which is easily accessible.
• Strip wiring-harness wire end (6).
• Cut preassembled wire end (7) to length and strip insulation.

Refer also to repair instruction:

Crimp butt connector on preassembled wire end.

Fig. 38: Crimping Butt Connector On Preassembled Wire End

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

Fig. 39: Identifying Shrink-Fit Hose

Crimp unused wire end to butt connector.

Fig. 40: Crimping Unused Wire End To Butt Connector

Pull shrink-on sleeve over butt connector.

Fig. 41: Pulling Shrink-On Sleeve Over Butt Connector

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. 42: Identifying Shrink-On Sleeve On Both Sides Of Shrink-Fit Hose

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