Notes
IMPORTANT:
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 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 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.
Fig. 42: Identifying Special Tools For Vehicle Electrical System Repairing
Choose repair kit.
Example: Repair kit, circular plug system D 2.5.
Fig. 43: Identifying Circular Plug System D 2.5
Remove following parts:
Fig. 44: Identifying Cables, Connectors And 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 kit 61 0 300 ).
See repair instructions
INSTRUCTIONS FOR OPENING CONTACTS AND LOCKS of different plug contact systems.
Fig. 45: Identifying Damage Cable With Socket Number
IMPORTANT:
Fig. 46: Identifying Special Tool
Adhere to following procedure:
Refer also to repair instruction: CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES
Crimp butt connector on pre-assembled wire end.
Special tools:
See repair instructions
CRIMPING ON STOP PARTS
Fig. 47: Identifying Special Tool
Push shrink-fit hose (8) onto free wire end.
Fig. 48: Identifying Shrink-Fit Hose
Crimp unused wire end to butt connector.
Fig. 49: Identifying Crimping Of Unused Wire End
Pull shrink-on sleeve over butt connector.
Fig. 50: Identifying 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.
Fig. 51: Identifying Shrink On Shrink-On Sleeve Ends