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. 67: 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

SPECIAL TOOLS FOR WIRING HARNESS REPAIRS

Special tools required:

• 12 1 080
• 61 0 200
• 61 0 210
• 61 0 220
• 61 0 230
• 61 0 300
• 61 0 400
• 61 1 190
• 61 4 320
• 61 9 041
• 61 9 044

Repair range, vehicle electrical system:

Release and press-out tool:

• Special tool 61 0 300
• Special tool 61 0 400 (MINI N12/N14)

Handling:

• Opening plug housings and removing contacts of different plug systems.

Fig. 68: Identifying Special Tool Kit

Cutting to length and stripping insulation from cables:

Handling:

• Cutting to length and stripping insulation from cables.

Fig. 69: Identifying Cutting Tool

Crimping stop parts (small contacts):

• Special tool 61 4 320
  1. Tool without crimping head
  2. Crimping head (stripping insulation and cutting fiber-optic cables to length )
  3. Crimping head (crimping fiber-optic cable contacts )
  4. Crimping head (crimping MQS contacts )
  5. Crimping head (crimping MPQ contacts )
  6. Replacement blade (face-cutting fiber-optic cables)
  7. Replacement blade with tool (insulation stripping unit)
  8. Universal crimping head (SI 2 04 06 293 )

Fig. 70: Identifying Crimping Stop Parts (Small Contacts)

Crimping stop parts (large contacts):

• Special tool 61 0 200 (crimping set)
• Special tool 61 0 210 (matrix set LSK 8)
• Special tool 61 0 220 (matrix set SLK 2.8)
• Special tool 61 0 230 (matrix set MAK 8 / DFK4)

Fig. 71: Identifying Crimping Stop Parts (Large Contacts)

Crimping antenna elbow plugs:

• Special tool 61 9 041 (hand crimping tool)
• Special tool 61 9 044 (matrix)

Handling:

• Antenna elbow plug on radio receiver

Fig. 72: Identifying Special Tool 61 9 041 And 61 9 044

Repair kit for ignition cables and for crimping fan connector receptacles 4 mm 2 :

• Special tool 12 1 080

Handling:

• Crimping stop parts (contacts).

Fig. 73: Identifying Repair Kit For Ignition Cables

Repairing ribbon cables:

• Special tool 61 1 190

Handling:

• Repairing ribbon cables

Fig. 74: Identifying Special Tool 61 1 190

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