Electrical System - Molded Wire Connector Repairs
87BMW02GROUP 61 Chassis - Electrical
Bulletin Number 61 04 87 (1416) Page 1 of 2
Montvale, NJ August 1987 Technical Dept.
SUBJECT: Repairs to Molded Wire Connectors
MODELS: All
Situation: Proper repairs to molded wire connectors are possible with the use of repair kit P/N 61 13 1 382 248 (see S.I. 61 03 87 (1413) for details), following the procedures listed below.
Improper repairs can lead to wrong ohmic values that will cause erroneous Check Control/warning light displays.
Repair
Procedures: 1) Remove molded wire connector from connector housing.
2) The wire of the affected connector has to be cut. Choose a location away from any other splices or harness branches. As there is plenty of wire on the replacement connector, avoid putting the splice next to the connector housing.
3) Cut the replacement connector wire to the same length as the wire of the removed connector.
4) Strip away about 1/2" of insulation on each wire.
5) Place a shrink tube over one of the wires being spliced before overlapping the wires.
6) Overlap the wires and crimp one of the splice clips into place. (Use crimping tool P/N 81 24 9 408 126 from BMW Electrical Repair Kit 1.)
7) Solder the wires and splice clip using 60/40 (tin/lead) rosin core solder.
8) Place the shrink tube over the splice and heat with a heat gun until tubing shrinks around the wires.
9) Place new molded wire connector into the connector housing and reconnect to component.