BMW X5: 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 the welds (2) on their longitudinal side.

The contacts of these connectors cannot be replaced. Replace plug completely.

Fig. 23: Identifying Ultrasonic-Welded Connectors

NOTE: Special tools referred to in the repair instructions below are contained in the following special tool kits:

Release and press-out tool 61 1 150

Replaced as from 09/2005 by: 61 0 300

61 0 400

Repair instructions for opening plug housings and removing contacts of different plug systems

For plug contact systems not listed, refer to appropriate Service Information:

Plug system D 1.5/D 2.5:

• Circular plugs, 7 -, 8-pin, System D 2.5
• Circular plugs, 13-pin, System D 2.5
• Circular plugs, 20-pin, System D 2.5
• Circular plugs, 4 -, 7-, 10 -, 12 -, 25-pin, System D 1.5/D 2.5
• In-line plugs, 15-pin, System D 2.5
• In-line plugs, 8-, 12-pin, System D 2.5
• In-line plugs, 30-pin, System D 2.5
• In-line plugs, 20-pin, System D 2.5

Plug system JPT/MDK/DFK:

• In-line plugs, 2-pin, System JPT ELA
• In-line plugs, 2-pin, System MDK 3plus 2.8
• In-line plugs, 4-pin, System DFK ELA

Plug system Elo/Elo-Power:

• In-line plugs, 4-, 10-pin, System Elo
• In-line plugs, 6-to 50-pin, System Elo
• In-line plugs, 3-, 6-pin, System Elo-Power 2.8

Plug system MQS/MPQ:

• In-line plugs, 6-, 8-pin, System MQS
• In-line plugs, 2-pin, System MPQ 2.8
• Control unit plugs, 25-, 35-, 55-, 83-, 88-pin
• In-line plugs, 24-pin, Hybrid System MQS/MPQ
• Socket housing 42-, 43-pin, Hybrid System MQS / MPQ
• Socket housings 2x21-, 2x27-pin, Hybrid System MQS/MPQ, Elo/Elo-Power
• In-line plugs, 30-pin, Hybrid System MQS/MPQ
• Socket housings, 5-, 8-pin, System MQS/MPQ
• Socket housing (radio plug), Hybrid System MQS/MPQ

UNLOCKING AND DISCONNECTING DIFFERENT PLUG CONNECTIONS

NOTE: Examples of unlocking and disconnecting different plug connections.

Press lock and open clip in direction of arrow.

Disconnect plug connection.

Fig. 24: Pressing Lock

Press lock and open clip in direction of arrow.

Disconnect plug connection.

Fig. 25: Opening Clip

Open clip in direction of arrow and disconnect plug connection in direction of arrow.

Fig. 26: Disconnecting Plug Connection

Press lock and disconnect plug connection in direction of arrow.

Fig. 27: Disconnecting Plug Connection

Press lock and disconnect plug connection in direction of arrow.

Fig. 28: Pressing Lock

Press lock and disconnect plug connection in direction of arrow.

Fig. 29: Disconnecting Plug Connection

Press lock and disconnect plug connection in direction of arrow.

Fig. 30: Pressing Lock

Press lock and disconnect plug connection in direction of arrow.

Fig. 31: Disconnecting Plug Connection

Fig. 32: Disconnecting Plug Connection

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