Butt connector for repairing a plug connection (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)
Special tools required:
- 61 0 300
- 61 4 340
- 61 0 240
- Identify cause of damage (e.g. sharp-edged body components, faulty electrical loads, jammed mechanisms, corrosion caused by ingress of water, etc.).
- Reading out the fault memory
- Eliminate cause of damage.
- Disconnect battery negative terminal
- 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: applicable BMW Parts Catalog)
- Carry out function test and read out fault memories again
- Eliminate new faults if applicable and clear fault memories
The case can no longer be ordered. Order individual parts for wiring harness repair through applicable BMW Parts Catalog.
Choose repair kit.
Example: Repair kit, circular connector system D 2.5.
Remove following parts:
- Pre-packaged end of cable with requisite wire cross-section
- Crimp connector for selected wire cross-section
- 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 and NOTES for opening contacts and locks of different plug contact systems.
- 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 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 mm2 )
- 61 0 240 (4.0 - 6.0 mm2 )
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.
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.
