BMW X3 Service & Repair Manual: Butt connector for repairing a plug connection

Special tools required:

• 61 0 300
• 61 4 340
• 61 0 240

IMPORTANT:

1. Identify cause of damage (e.g. sharp-edged body components, 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 circuit diagram (e.g. antilock braking system, active rear-axle kinematics, airbags, etc.) are influenced. Otherwise replace faulty wiring harness or use repair cable (sourcing reference: BMW Parts Department)
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.

Choose repair kit.

Example: Repair kit, circular connector system D 2.5.

Remove following parts:

1. Pre-packaged end of cable with requisite wire cross-section
2. Crimp connector for selected wire cross-section
3. Shrink-fit hose

Open secondary lock on housing.

Mark damaged contact (4) with socket number of housing and press it out of housing using appropriate special tool contained in special tool set 61 0 300 ).

See repair instructions

NOTES FOR OPENING CONTACTS AND LOCKS of different plug contact systems.

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.

Adhere to following procedure:

• Cut off wire with faulty contact at point which is easily accessible
• Strip insulation from end of wire at wiring harness end
• Cut preassembled wire end to length and strip insulation

Refer also to repair instruction:

CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES

Crimp butt connector on preassembled wire end.

Special tools:

• 61 4 340 (0.35 - 2.5 sq mm)
• 61 0 240 (4.0 - 6.0 sq mm)

See repair instructions

CRIMPING ON STOP PARTS

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

Crimp unused wire end to butt connector.

Pull 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.