BMW X5 Owners & Service Manuals

BMW X5: Butt Connector For Repairing A Plug Connection

Special tools required:


  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:

Plug Connection, Terminals
Fig. 33: Identifying BMW Special Tool Kit

Choose repair kit.

Example: Repair kit, circular plug system D 2.5.

Plug Connection, Terminals
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

Plug Connection, Terminals
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.

Plug Connection, Terminals
Fig. 36: Removing Damaged Contact


Plug Connection, Terminals
Fig. 37: Identifying Cutting Tool

Observe following procedure:

Refer also to repair instruction:

Crimp butt connector on preassembled wire end.

Plug Connection, Terminals
Fig. 38: Crimping Butt Connector On Preassembled Wire End

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

Plug Connection, Terminals
Fig. 39: Identifying Shrink-Fit Hose

Crimp unused wire end to butt connector.

Plug Connection, Terminals
Fig. 40: Crimping Unused Wire End To Butt Connector

Pull shrink-on sleeve over butt connector.

Plug Connection, Terminals
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.

Plug Connection, Terminals
Fig. 42: Identifying Shrink-On Sleeve On Both Sides Of Shrink-Fit Hose


 Crimping Stop Parts

Special tools required: 12 1 080 12 1 081 12 1 083 Spare parts for in-car electronics (housing and contacts): Crimping butt connectors and contact sleeves for fan connectors up to 2.5 mm2 Cr

 Installing Fan Connector For Retrofitting/Repairs

Special tools required: 61 9 040 61 9 041 61 9 042 NOTE: The repair range IV for vehicle electrical system contained the required special tools and individual parts for retrofitting and repair w

 Opening Plug Housings And Removing Contacts Of Different Plug Systems

Special tools required: 61 0 300 61 0 400 61 1 150 Abbreviations and what they mean: ABBREVIATIONS MEANINGS Ultrasonic-welded connectors: Ultrasonic-welded connectors (1) can be identified by t


 Piston With Rings And Pin

REMOVING AND INSTALLING/REPLACING ALL PISTONS (N52K) Special tools required: 00 9 120 TORQUE ANGLE MEASURING DIAL 11 4 491 11 4 492 11 4 493 11 4 494 11 6 241 11 6 261 11 8 330 WARNING: Danger of injury! Carry out work on piston pin circlip wearing protective goggles only. IMPORTANT: If pi

 Removing And Installing/Replacing Mechanism For Floating Roofliner

Necessary preliminary tasks: Remove glass slide/tilt sunroof. Remove slider set for floating roofliner. Remove rear crossmember. Unclip end stops (1) on left and right from guide channel. Fig. 22: Uncoupling End Stops Unclip floating roofliner cover plate (1) from slider for front sun shield.

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