Table of Contents

Testing Cables and Breakout Boxes

Subject Page

Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Connector Contact Removal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Socket and Spring Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Instrument Cluster Illumination Bulb Holder Removal Socket . . . . . .6
Relay Holder Disengaging Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Circular Connector Lock Disengager . . . . . . . . . . . . . . . . . . . . . . . . . . .7
BMW Plug System Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Plug System D1.5/D2.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Circular Plug 7-8 Pin System D2.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Circular Plug 20 Pin System D2.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Circular Plug 4-7-10-12-25 Pin System D1.5/D2.5 . . . . . . . . . . . . . .9
In-line Plug 15 Pin System D2.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
In-line Plug 8-, 12 Pin System D2.5 . . . . . . . . . . . . . . . . . . . . . . . . . . .10
In-line Plug 20 Pin System D2.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
In-line Plug 30 Pin System D2.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Plug System JPT/MDK/DFK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
In-line plug 2 Pin System JPT ELA . . . . . . . . . . . . . . . . . . . . . . . . . . .12
In-line plug 2 Pin System MDK 3 plus 2.8 . . . . . . . . . . . . . . . . . . . . .12
In-line plug 4 Pin System DFK ELA . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Plug System Elo/Elo-Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
In-line Plug 3-,6 Pin System Elo-Power 2.8 . . . . . . . . . . . . . . . . . . . .14
In-line plug 4-,10 Pin System Elo . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
In-line Plug 6-,50 Pin System Elo . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Plug System MQS/MPQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
In-line Plug 6-,8 Pin System MQS . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
In-line Plug 2 Pin System MPQ 2.8 . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Control Unit Plug 25-, 35-, 55-,83-,88 Pin . . . . . . . . . . . . . . . . . . . .17
In-line Plug 24 Pin Hybrid System MQS/MPQ . . . . . . . . . . . . . . . . . .17
Socket Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Pin Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Socket Housing 42-,43 Pin Hybrid Systems MQS/MPQ . . . . . . . . .19
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Socket Housing 2x27-, 2x27 Pin Hybrid System MQS/MPQ,
Elo/Elo Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
In-line Plug 30 Pin Hybrid System MQS/MPQ . . . . . . . . . . . . . . . . . .20
Socket Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Initial Print Date: 05/01 Revision Date: 10/10
Subject Page
Pin Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Socket Housing 5-, 8 Pin System MQS/MPQ . . . . . . . . . . . . . . . . . .21
Socket housing 5pin (Hybrid System MQS/MPQ) . . . . . . . . . . . . . .21
Socket Housing 8 Pin (MQS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Socket Housing (Radio Plug) Hybrid System MQS/MPS . . . . . . . . .22
Removing MPQ Contacts from Radio Plug . . . . . . . . . . . . . . . . . . . . .22
Removing MQS Contacts from Carrier . . . . . . . . . . . . . . . . . . . . . . . .23
Removing MPQ Contacts from Contact Carrier . . . . . . . . . . . . . . . . .23
Miscellaneous Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Fuse Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
ECM Main Relay Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Solderless Terminals And Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Electrical Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Electrical Repair Kit IV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Cable Stripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Crimping Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Cable Stripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Crimping Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Prepackaged Wiring Repair Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Soldering Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Soldering Preparation and Procedure . . . . . . . . . . . . . . . . . . . . . . . . . .31

Break Out Boxes and V Cables,Tester and Adapter Sets . . . . . . . .32

Breakout Boxes and “V” Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
55 pin Breakout Box P/N 81 12 9 425 091 . . . . . . . . . . . . . . . . . . . .33
83 Pin Breakout Box (Red Face) P/N 90 88 6 614 420 . . . . . . . . .33
88 Pin Breakout Box (Green Face) P/N 88 88 6 614 410 . . . . . . . .33
134 Pin SKE Control Module Breakout Box Set
P/N 90 88 6 121 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
26 Pin Breakout Box P/N 88 88 6 611 459 . . . . . . . . . . . . . . . . . . . .34
60 Pin Breakout Box P/N 90 88 6 614 390 . . . . . . . . . . . . . . . . . . . .34
“V” Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Tester and Adapter Set for Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Subject Page

BLANK
PAGE
Testing Cables and Breakout Boxes
Model: All

Production: All

After completion of this module you will be able to:

• Recognize and distinguish the various Electrical Repair Kits.

• Use the Connector Removal Kit.

• Recognize the plug configurations and disassemble them properly.

• Repair wiring harnesses and connectors.

• Choose the proper Breakout Box and “V” cable for testing.

• Use the relay testing tool.

4
Testing Cables and Breakout Boxes
Connectors
Connector Contact Removal Kit
The connector contact removal kit provides
tools for the disassembly of connectors.
Proper use of these tools enable the techni-
cian to access wiring connectors for repairs
equal to factory quality.
Always refer to the latest Service Information
Bulletins (Group 04) for up to date information
regarding new tools.
The Connector Contact Removal Kit
is used for:
Current P/N 88 88 6 611 150
• Releasing round plug housings.
• Pressing out contacts.
• Pulling out indicator lamps.
• Releasing relay carriers.

Socket and Spring Contacts

Socket and Spring contacts compress the springs while the connector is pushed from
the housing.

5
Testing Cables and Breakout Boxes
Flat spring contacts depress the spring allowing the connector to be pushed or gently
pulled from the connector housing.

Instrument Cluster Illumination Bulb Holder Removal Socket

The backlighting illumination bulbs are

removed from the cluster by placing square
head of the socket on the bulb holder and
turning 90° counter clockwise.
The bulb removal socket is used on all instru-
ment clusters.

Relay Holder Disengaging Tool

This tool allows the relay holder (2) to disen-

gage the relay connector (1).

6
Testing Cables and Breakout Boxes
Circular Connector Lock Disengager
These tools unlock the circular connector hous-
ings allowing the individual connectors to be
removed.
The various sizes are reflected in the part num-
bers:
4 pin = 61 1 141
7 pin = 61 1 142
10 pin = 61 1 145
12 pin = 61 1 143
25 Pin = 61 1 144

BMW Plug System Abbreviations

D 1.5/2.5 Round contacts of 1.5mm or 2.5mm diameter

MDK 3 Plus Miniature double flat spring contact

JPT ELA Junior Power Timer flat spring contacts with strand sealing

DFK ELA Double flat spring contacts with strand sealing

Elo Electronic contacts with and without strand sealing

Manufacturer: Siemens

Elo Power Electronic contacts for heavy loads with and without strand sealing
Manufacturer: Siemens

MQS Micro Quadlock System electronic contacts with and without strand
sealing
Manufacturer: AMP

MPQ Micro Power Quadlock electronic contacts for heavy loads with and
without strand sealing
Manufacturer: AMP
7
Testing Cables and Breakout Boxes
Plug System D1.5/D2.5
Circular Plug 7-8 Pin System D2.5
• Pull off the rubber boot (1).
• Push the retaining lugs (2) of the inner connector section 3 inward carefully to disen-
gage the lock notch.
• Push the inner connector section (3) in the direction of the arrow in the illustration
until the retaining lugs (2) are in the recessed notch (4) and use the appropriate
sized spring contact tool and remove the connector from the housing.

Circular plug 13 Pin System D2.5

• Carefully pull off the rubber grommet (1).
• Pull the lock retainers (2) outward (direction of arrows) to allow the lock notch to dis-
engage.
• Pull the inner section (3) upward as shown in the illustration until the lock notches (4)
are in the released position of the lock retainers (5) and use the appropriate size
spring contact and remove the connector from the housing.

8
Testing Cables and Breakout Boxes
Circular Plug 20 Pin System D2.5

• With the boot pulled back, press the lock tabs (1) of the inner connector section (2)
inward.
• Simultaneously, rotate the inner connection section (2) counter clockwise to allow
the lock tabs (1) to engage in the unlocked position and use the appropriate sized
spring contact and remove connector from the housing.

Circular Plug 4-7-10-12-25 Pin System D1.5/D2.5

• Insert the appropriate unlocking tool (determined by the number of pins) into the
connector.
• The connector is unlocked when the lock tab (3) is in the unlocked position (1).
The connector is locked when the lock tab (3) is in the locked position (2).
• Use the appropriate sized spring contact and remove connector from the housing.

9
Testing Cables and Breakout Boxes
In-line Plug 15 Pin System D2.5

• Pull the outer connector section (1) slightly outward in the area of lock tabs (2).
• Simultaneously, slide the inner connector section (3) in the direction of the arrow to
the unlocked position.
• Use the appropriate sized spring contact and remove connector from housing.

In-line Plug 8-, 12 Pin System D2.5

• Slide the upper section (1) and the lower section (2) of the connector in opposite
directions to unlock the connector.
• Using special tool 61 1 132 press the spring latch down and pull the connector (3)
from the housing.

10
Testing Cables and Breakout Boxes
In-line Plug 20 Pin System D2.5

• Pull locking slide (1) completely out of connector (2).

• Using special tool 61 1 132 press the spring latch down and pull the connector from
the housing.

In-line Plug 30 Pin System D2.5

• Pull the outer section (1) slightly outward in the area of lock tabs (2).
• Simultaneously, slide the inner connector section (3) in the direction of the arrow to
the unlocked position.
• Use the appropriate sized spring contact and remove connector from housing.

11
Testing Cables and Breakout Boxes
Plug System JPT/MDK/DFK

In-line plug 2 Pin System JPT ELA

• Press lock (1) in direction of arrow and slide plug forward.

• Press lock (1) downward and slide out to one side.
• Unlock contact with special tool 61 1 136 and pull out cable (2) and contact
towards rear.

In-line plug 2 Pin System MDK 3 plus 2.8

• Unlock lock (1) on outside at arrester hook and slide out lock (1) side.
• Unlock contact with special tool 61 1 136 and pull out cable (2) and contact
towards rear.

12
Testing Cables and Breakout Boxes
In-line plug 4 Pin System DFK ELA

• Press arrester hook in direction of arrow

and remove lock (1).
• Unlock contact with special tool 61 1
136 and pull cable and contact out
towards rear.

Installation Instructions

• If necessary, slide lock must also be

unlocked with screw driver.

Notes:

13
Testing Cables and Breakout Boxes
Plug System Elo/Elo-Power

In-line Plug 3-,6 Pin System Elo-Power 2.8

• Press unlocking hook (1) in direction of arrow and disengage. Then unlock locking
hook (2) and remove lock.
• Press down arrestor hook (3) with screwdriver and pull out cable with contact
towards rear.

In-line plug 4-,10 Pin System Elo

• Slide connector lock (1) off of main connector body.

• Push the lock tab of the connector being removed down (3) with pin or small screw-
driver in the primary lock slot(4) and pull the wire out (5) to the secondary lock
position (6).
• Push the lock tab down again in the secondary lock position and remove wire com-
pletely.

14
Testing Cables and Breakout Boxes
In-line Plug 6-,50 Pin System Elo

• Unlock lock (Fig. 14/1).

• Unfasten cable clip (Fig. 14/2).
• Slide connector lock (1) off of main connector body (2) (Fig. 14/3).
• Push the connector plate (3) out of connector shell using a small screwdriver
through hole on end of connector body (Fig. 14/4).
• Push the lock tab of the connector being removed down (6) with pin or small screw
driver in the primary lock slot (7) and pull the wire out to the secondary lock position
(8) (Fig. 14/5).
• Push the lock tab down again in the secondary lock position and remove wire com-
pletely (Fig. 14/6).

Fig. 14/1 Fig. 14/2 Fig. 14/3

Fig. 14/4 Fig. 14/5 Fig. 14/6

15
Testing Cables and Breakout Boxes
Plug System MQS/MPQ

In-line Plug 6-,8 Pin System MQS

• Press lock (1) in direction of arrow and slide plug forward.

• Press locking hook (2) downward and slide lock (1) out.
• Press down arrester hook (3) with screwdriver and pull out cable with contact
towards rear.

In-

line Plug 2 Pin System MPQ 2.8

• Press catch on outside in direction of arrow and remove towards top.

• Press down arrestor hook (1) with screwdriver and pull out cable and contact (2)
towards rear.

16
Testing Cables and Breakout Boxes
Control Unit Plug 25-, 35-, 55-,83-,88 Pin

• Remove phillips head screws (1) from connector. Gently pivot the connector plate
(2) with seal (3) out of the connector shell.
• Remove seal (3) and pull connector plate lock (4) out of locked position.
• Using the appropriate sized spring contact and remove connector (5) from housing.

In-line Plug 24 Pin Hybrid System MQS/MPQ

Manufactured by AMP: The following contact types without strand sealing can be
fitted in the plug housings:
MQS (Micro Quadlock System)
MPQ, width 2.8 mm (Micro Power Quadlock)
MPQ, width 5.2 mm (Micro Power Quadlock)

Socket Housing

• Press locks (1) on cap (2) upwards on

both sides.
• Detach cap from contact carrier (3).

Note: Detaching the cap releases the

secondary lock of the socket
contacts.

17
Testing Cables and Breakout Boxes
 • Hold down retaining hook (1) of socket
contact carrier with a small screwdriver.
• Pull wire with socket contact in direction
of arrow as far as secondary lock (2).
(Fig. 17/1)
• Hold down retaining hook in secondary
lock (1) again and pull cable with socket
contact (2) completely out of contact carri-
er (3).
(Fig. 17/2)

Pin Housing
• Press locks (1) on cap (2) upwards on Fig. 17/1
both sides.
• Detach cap from housing carrier (3)
(Fig. 17/3).

Note: Detaching the cap releases the

secondary locks of the pin contacts
in the contact carriers.

• Pull contact carrier (1) out of housing

carrier (2) (Fig. 17/4).
• The pin contacts are pulled of a contact
Fig. 17/2
carrier as described under “Socket
Housing”.

Fig. 17/3 Fig. 17/4

18
Testing Cables and Breakout Boxes
Socket Housing 42-,43 Pin Hybrid Systems MQS/MPQ

Manufactured by AMP: The following contact types without strand sealing can be
fitted in the socket housings:
MQS (Micro Quadlock System)
MPQ, width 2.8 mm (Micro Power Quadlock)
MPQ, width 5.2mm (Micro Power Quadlock)

• Open secondary locks (1) on socket housing.

• Press back retaining hook of MQS contacts (2) with special tool 61 1 134 and pull
out cable with contact.
• Press back retaining hook of MPQ contacts (3) with screwdriver or similar tool and
pull out cable with contact.

Installation Instructions
• Bend open retaining hook of contacts gently before inserting into plug housing.
• To install contacts, observe cavity numbers on reverse side of socket housing.

Socket Housing 2x27-, 2x27 Pin Hybrid System MQS/MPQ, Elo/Elo Power

Manufactured by Amp: The following contact types without strand sealing can be
fitted in the socket housings:
MQS (Micro Quadlock System)
MQS, width 2.8 mm (Micro Power Quadlock)
MPQ, width 5.2 mm (Micro Power Quadlock)

19
Testing Cables and Breakout Boxes
 Manufactured by Siemens: The following contact types without strand sealing can
be fitted in th socket housings:
Elo (electronic contact)
Elo-Power 2.8 mm wide (electronic contact for heavy loads)
Elo-Power 5.2 mm wide (electronic contact for heavy loads)

• Raise lock (1) on housing (2).

• Push contact carrier (3) from rear out of
housing.

Note: The second carrier is pushed out in

the same way. Pushing out the
contact carrier releases the sec-
ondary locks of the secondary con-
tacts.
Procedure for removing contacts are same as for other
Elo/Elo-Power Systems, refer to those instructions.

In-line Plug 30 Pin Hybrid System MQS/MPQ

Manufactured by AMP: The following contact types without strand sealing can be
fitted in the plug housings:
MQS (Micro Quadlock System)
MPQ, width 2.8 mm (Micro Power Quadlock)
MPQ, width 5.2 mm (Micro Power Quadlock)

Socket Housing
• Raise lock (1) on housing (2).
• Push contact carrier (3) from rear out of
housing (2).

Note: Pushing out the contact carrier

releases the secondary locks of the
socket contacts.

Procedure for removing contacts are same as for other

Elo/Elo-Power Systems, refer to those instructions.

20
Testing Cables and Breakout Boxes
Pin Housing
• Contact 1...13 and 19...27.
• Raise locking slide(1) on both sides (2) of housing and detach.

Note: Detaching the locking slide releases the secondary locks of the
pin contacts.

• Contacts 14...18 and 28...30.

• Pull slide (1) outward completely.
• Raise lock (2) on housing.
• Pull contact carrier out of housing.

Note: Pulling out the contact carrier releases the secondary locks of
the pin contacts.

Socket Housing 5-, 8 Pin System MQS/MPQ

Manufactured by AMP: The following contact types without strand sealing can be fit-
ted in the socket housings:
MQS (Micro Quadlock System)
MPQ, width 2.8 mm (Micro Power Quadlock)
MPQ, width 5.2mm (Micro Power Quadlock)

Socket housing 5pin (Hybrid System

MQS/MPQ)
• Raise fastener (1) (slide) by way of retaining
lug (2) and detach from contact carrier (3).

21
Testing Cables and Breakout Boxes
Socket Housing 8 Pin (MQS)

• Raise fastener (1) (slide) by way of retaining

lug (2) and detach from contact carrier (3).

Procedure for removing contacts are same as for other

Elo/Elo-Power Systems, refer to those instructions.

Socket Housing (Radio Plug) Hybrid System MQS/MPS

Manufactured by AMP: The following contact types without strand sealing can be
fitted in the plug housings:
MQS (Micro Quadlock System)
MPQ, width 2.8 mm (Micro Power Quadlock)
MPQ, width 5.2 mm (Micro Power Quadlock)

Removing MPQ Contacts from Radio Plug

• Press lock (1) in direction of arrow, detach secondary lock (2) from radio plug.
• Feed special tool 61 1 135 past side of contact.
• Press special tool 61 1 135 in direction of arrow.
• Pull wire (1) with socket contact out of radio plug(2).

22
Testing Cables and Breakout Boxes
Removing MQS Contacts from Carrier

• Press lock (1) in direction of arrow and pull housing (2) out of radio plug (Fig. 22/1).
• Press lock (1) in direction of arrow. Pull contact carrier (2) out of housing (Fig. 22/2).

Note: When the contact carrier is pulled out, the secondary locks of the socket
contacts are raised.
Procedure for removing contacts are same as for other
Elo/Elo-Power Systems, refer to those instructions.

Fig. 22/1 Fig. 22/2

Removing MPQ Contacts from Contact Carrier

• Remove contact carrier (1) with MQS contacts from radio plug. Raise lock (2)
on radio plug. Pull contact carrier (3) out of radio plug (Fig. 22/3).
• Press lock (1) in direction of arrow. Pull secondary lock (2) in direction of arrow
completely out of contact carrier (3) (Fig. 22/4).
• Press special tool 61 1 135 on inside of contact into contact carrier(2). Pull wire
with socket contact (1) out of contact carrier (2) (Fig. 22/5).

Fig. 22/3 Fig. 22/4 Fig. 22/5

23
Testing Cables and Breakout Boxes
Miscellaneous Connectors
Fuse Strip

• Pull appropriate fuse from fuse strip (1).

Note: Mark fuse rating and position for reinstallment.

• Pull locking slide (2) out of fuse strip until stop is felt.
• Using special tool 61 1 136 or 61 1 1

ECM Main Relay Connector

• Unlock wire flap (1) of connector being removed.

• Using special tool 61 1 136 or 61 1 137 press the spring latch down (2) and pull
the connector from the housing.37 press the spring latch down (3) and pull the con-
nector from the housing.

24
Testing Cables and Breakout Boxes
Solderless Terminals And Connectors
Mechanical strength of solderless terminal design and electrical conductivity must be
maintained at all times. To ensure these characteristics are maintained in the vehicles
electrical system several BMW repair kits are available.
The repair kits listed contain all the approved
connectors, pins, and tools required for proper
repair of BMW's electrical, electronics compo-
nents.
• Electrical Repair Kit IV
P/N 90 88 6 619 020
The Electrical Repair Kit IV (Ref. SI. 04 18 92)
is used in conjunction with the instruction
manuals and detailed repair manual proce-
dures from Group 61, Sub-group 13
found in TIS.

These procedures include:

• Disassembling, replacing a plug connection on the various types of connectors.
• Cutting cable to length.
• Crimping stop parts (Contacts).
• Butt connectors for repairing a plug connection.
Operating instructions for special tools and the
handling of individual parts in the repair kit are
available under PN 61 9 029.
Three previous kits issued by BMW are:
• Electrical Repair Kit I (Black Case)
P/N 81 24 9 408 080
• Electrical Repair Kit II (Blue Case)
P/N 81 24 9 408 300
• Electrical Repair Kit III (Red Case)
P/N 82 11 9 408 400
Electrical repair kits I, II and III are primarily needed for repairing wiring harness and con-
nectors of older vehicles (E30 and earlier). Refer to repair kit instructions, SI bulletins and
repair manual microfiche. Operating instructions for special tools in these kits are avail-
able under PN 61 8 084.

25
Testing Cables and Breakout Boxes
Electrical Repair
Electrical Repair Kit IV
The Electrical Repair Kits (I,II,III and IV) have
gone through various upgrades.
Electrical Repair Kit IV (PN 90 88 619 020)
has been developed to handle repairs of the
specialized state of the art wiring and har-
nesses of the newest BMW products.

Caution:
The special tools contained in the Electrical
Repair Kits I,II,III are not state of the art and are
not suitable for specialized wiring harness
repairs.

Use exclusively Electrical Repair Kit IV for those

repairs.

Electrical Repair Kit IV (61 9 020)

Contains the following:
61 9 041 Crimping Tool
61 9 042 Matrix
61 9 043 Cable Stripper
61 9 044 Matrix
Assorted Individual Parts

Cable Stripper
Special Tool 61 9 043 Cable stripper with
wire cutter for cutting and stripping insula-
tion from cables.

Crimping Tool
Special Tool 61 9 041 Crimping Tool with
special tool 61 9 044 (matrix) for crimping
cable guide and strain relief device on anten-
na elbow plug.
Supplementary kits for Electrical Repair Kit IV are
released periodically. Check the latest Service Bulletin
to insure information on latest connectors are avail-
able.

26
Testing Cables and Breakout Boxes
Cable Stripping
Proper wire stripping and connector replace-
ment is essential to ensure the integrity of the
electrical connection. Always follow specific
instructions in the Electrical Repair Kit IV
instruction manual as well as Group 61 - 13
repair manual found in the TIS.
The length of wire to be stripped is deter-
mined by the wire gauge.

Wire cross-section size Stripped length:

mm2 mm
0.35 ... 0.50 4.0
0.75 ... 1.00 4.5
1.00 ... 2.50 5.0

Proper use of the wire stripping tool will pro-

vide consistently positive results. Insert the
wire (1) into the stripper. Stop the wire when
the required strip length is past the cutter (2).
Squeeze the handle of the tool.

When the top jaw of the tool touches the wire

(3) the mechanism shifts the clamping action
to a pulling action which strips the wire of the
insulation (4).

27
Testing Cables and Breakout Boxes
Crimping Tool
Use the wire crimper from the BMW
Electrical Repair Kit. This crimper is
designed for the specific connectors found in
BMW automobiles. Proper use of the tools
will provide consistent good quality connec-
tor crimps.
The crimper is designed to apply just the
right amount of pressure based on the wire
gauge and connector size.
The tool has removable crimper jaws (3). This
feature allows for an unlimited number of
connector types for future compatibility. The
repair manual refers to the different sized
crimping slots as “Nests”. The gauge of the
wire being crimped determines which “Nest”
is used.

Nest Wire cross-section size

1 0.35 ... 0.50mm2
2 0.75 ... 1.00mm2
3 1.50mm2
4 2.50mm2

Example:
A .75 - 1.0mm gauge wire requires nest 2 for
proper crimping.
Throughout the Electrical Repair Kit instruc-
tion manual are illustrations of various con-
nectors being crimped. The highlighted box
of the 16 box grid in these illustrations refers
to the storage compartment in the electrical
kit drawers in which that specific connector
can be found.
Insert the “crimping end” of the connector
into the appropriate “nest”. Illustration pro-
vides example of comb replacement connec-
tor (4) and inline splice connector (5).

28
Testing Cables and Breakout Boxes
Squeeze the tool handle slightly to set the
tool in the first ratchet latch position. This will
hold the connector in the tool without closing
the crimp (6).
Insert the stripped wire into the receiving end
of the crimper tool making sure the wire is
inserted far enough to ensure that only the
wire insulation will be inside the insulation
support barrel (7).
Properly crimped connectors exhibit the fol-
lowing characteristics:

• The insulation support barrel will be

crimped consistently and snug against
the insulation. The insulation will not be
crushed (8).
• A bellmouth crimp will be visible at the
wire end of the of the wire barrel (9).
• Wire strands will be visible at the contact
end of the wire barrel (10).
• Insulation end will be visible in this area
(11) (Fig. 27/1).

The following are examples of unacceptable crimps: (Fig. 27/2)

• Excessive or no wire strands at the contact end of the wire barrel (10).
• Excessive or no insulation end in the acceptable area (11).

Fig. 27/1 Fig. 27/2

29
Testing Cables and Breakout Boxes
Prepackaged Wiring Repair Sets
Included with the Electrical Repair Kit IV are a
variety of wiring repair sets. These sets con-
tain various pre-crimped wiring connectors on
assorted gauge wire lengths for simple splice
connection repair into a wiring harness.
The repair kits also contain:
1. Various gauge lengths of wire
with pre-crimped connectors.
2. In-line splice connectors.
3. Heat shrink tubing.
When used correctly the in-line splice con-
nectors provide a BMW factory approved wire
crimp. Use the correct size nest in the
crimper tool and connect one side of the in-
line crimp with the wire.
Slide a piece of heat shrink tubing on the wire
and crimp the other side of the in-line con-
nector.
Use a heat gun to shrink the tube around the
splice connector to provide a moisture resis-
tant seal.

Part numbers for the wire sets or any compo-

nent of all four electrical repair kits can be re-
ordered from:
• The P/N reference card inside each
repair kit.
• Special tools microfiche.
• The Electrical Repair Kit 1-4 compo-
nent catalog (SD 92-036).

As new connectors are developed for new vehicles, the repair kits will be announced by
Service Information bulletins and sent to dealerships via automatic tools shipment.

30
Testing Cables and Breakout Boxes
Soldering Connections
In the event that a wiring connection must be
soldered in a vehicle’s electrical system, there
are certain procedures which must be fol-
lowed. Improper soldering will result in poor
electrical connections or damage to electrical
components.

SAFETY: Adhere to the following basic

guidelines when preparing to
solder.

• Safety glasses must be worn.

• Disconnect vehicle battery.
• Cover vehicle trim surfaces.
• Exercise your common sense.
• Provide adequate ventilation,
it’s the best safety precaution!

Soldering Preparation and Procedure

• The wire insulation must be stripped to

expose an adequate amount of bare wire
(not too little-not to much.)
• The wires and or connectors must be
clean and free of grease, dirt, wax, etc.
• A thin coating of rosin core flux must be
applied to the soldering connection.
• Have enough 60/40 (tin/lead) general electrical solder on hand prior to starting.
• If heat transfer to a heat sensitive component is possible use “heat sinks”.
• Use a soldering gun tip that is the right size for the job. Do not use an overly large
tip which could melt wire insulation and block your view of what is being soldered.
• The soldering tip must be “tinned”. This means to keep a thin layer of solder on the
tip at all times during soldering. This will transfer the heat quickly and allow the sol-
der to flow easily into the joint being soldered.
• Preheat the wires or connector. Introduce the solder into the joint not the soldering
tip.
• When the solder starts to flow allow it to infiltrate the joint only for a moment.
Almost simultaneously, pull the tip off of the joint to prevent overheating.
• A properly soldered joint will be smooth, shinny, and even surfaced.
31
Testing Cables and Breakout Boxes
Break Out Boxes and V Cables,
Tester and Adapter Sets
Breakout Boxes and “V” Cables
Breakout Boxes are used to:
• Provide a convenient “tap” into an electrical circuit.
• Minimize the possibility of damage to control unit connections and wire harnesses
during diagnosis of electrical/electronic systems.
• Ensure solid meter connections for proper diagnosis, this in turn will help the tech-
nician to be more organized and efficient.
• Provide easier access to circuits for testing with equipment such as, multimeter,
DISplus tester or other diagnostic tools.
CAUTION: Breakout box cable connections are universal in order to fit the
varying coded connectors found in the vehicles. Always confirm
that you are connecting the correct control module into the sys-
tem harness that is on the other side of the breakout box. System
damage will occur if it is not the correct system.

Example: DME and EGS/AGS control modules both utilize an 88 or 134 pin control
module. These control modules reside in the same E-Box on most vehicles. The con-
trol modules are coded to prevent unintentional cross connecting at the vehicle harness.
But, this connector coding is not present on the 88 or 134 pin breakout box(s). Result:
A DME control module could be connected to a transmission control system.
Damage will result!
Several different types of breakout boxes are available depending on the particular sys-
tem being diagnosed.

MOTRONIC

32
Testing Cables and Breakout Boxes
55 pin Breakout Box
P/N 81 12 9 425 091

Used with control modules that have single

multi-pin plugs from 25 to 55 pins.

• L-jetronic
• ABS
• Motronic
• EGS
Adapter cables are required.

83 Pin Breakout Box (Red Face)

P/N 90 88 6 614 420

When used with ABS/ASC 5 system, no

adapter cables are required. See SIB 04 10
95 about an adapter harness for use with the
Teves Mark IV G ABS system of the E36.

88 Pin Breakout Box (Green Face)

P/N 88 88 6 614 410

Used with control units that have up to 88 pins;

• DME
• EGS/AGS
• ZAE/MRS
• LCM
No adapter cables are required when con-
nected to a DME or EGS/AGS control mod-
ule. See SIB’s 04 26 96 and 04 15 96 about
adapter harnesses for ZAE/MRS and LCM
systems.
33
Testing Cables and Breakout Boxes
134 Pin SKE Control Module
Breakout Box Set
P/N 90 88 6 121 300

The 134 pin modular connector DME and

AGS control modules use a combination of
breakout boxes for troubleshooting. The part
number above provides three breakout boxes
and five adapter harnesses. The two outside
edge connectors use the familiar 26 pin
breakout boxes. The three inside connectors
use the boxes from the ordered set.

26 Pin Breakout Box

P/N 88 88 6 611 459

Used with system or peripheral control mod-

ule that have up to 26 pins. This breakout
box is used in conjunction with adapter
cables called “V” Cables. There are many dif-
ferent types of “V” cables for the various con-
nectors found on the vehicles.

60 Pin Breakout Box

P/N 90 88 6 614 390

Used for connecting all adapter leads with 27

pin to 60 pin plug connections.

34
Testing Cables and Breakout Boxes
“V” Cables

“V” cables are available in different versions

depending on the system being diagnosed.
Always refer to the most recent Service infor-
mation for the required special tools.

“V” cables are only used with the 26 pin break-

out box to access input and output signals of
peripheral modules and systems.

• The appropriate cable is distinguished by the color of the connector end.

• The color will match the particular modules connector color. Unless the color
matches, the cable will not fit the connector on the module being tested.
• Each colored “V” cable has a series of alignment tabs that will only fit it’s particular
module or system.

“V” cables with ELO connectors are also being used with the 26 pin breakout box.
These cables are unique in that they have a locking arm on the component side of the
cable. They are light green in color, and the number of pins will vary depending on the
system being tested.
“V” harness adapters were introduced with the E38. These also have light green ELO
connectors on the component side, but they do not require a breakout box. There is a
black plug on one side with same number of pins as the component being tested. The
plug has numbers stamped on it’s side that corresponds with the pins on that particular
component. You access the signals by plugging the test equipment directly into those
pin numbers.
As new systems and components are being introduced, new breakout boxes and cables
will also be introduced.
Always remember to refer to the most recent service information in TIS or Service
Information Bulletins for the latest diagnostic tools and procedures.

35
Testing Cables and Breakout Boxes
Tester and Adapter Set for Relays

The Relay Adapter provides a platform to test a

relay while allowing the relay to remain active in
a circuit.
The adapters included enable different pin con-
figurations of relays to be tested using a single
tester.

Remove relay and compare plug in adapter with

plug pattern on relay. Choose correct adapter Fig. 33/1
(Fig. 33/1).

Fit adapter to Measuring bridge, noting the

marker arrows (A). Fit the relay to the measuring
bridge (Fig. 33/2).

Plug the assemble measuring bridge into the

socket of the relay to be checked. Test using a
multimeter. See the circuit diagram, testing
instructions and repair manual for subsequent
procedure (Fig. 33/3).
Fig. 33/2 Fig. 33/3

36
Testing Cables and Breakout Boxes
Examples of V cables
Part number Description Chassis Use
61 1 260 30 Pin V cable E46 Wiring door harness
61 1 270 24 Pin V Cable E46 Connection on seat plug
61 1 460 Set of 8 cables E32,36,38 Door harness and others
61 1 480 Set of 7 cables E30,32,34 Various electrical systems
61 1 490 Set of 2 cables E34 Engine wiring harness
61 2 050 2 Pin V cable (JPT) E31,32,34 Servotronic
61 2 070 Set of 3 cables E36,38,46, Electrical front seat
61 3 030 V cable E38 DSC 3 control module
61 3 150 54 Pin adapter E46 Light module
61 3 190 Test Leads E38,39 EWS
61 3 210 5 Pin V cable E46 Seat heating
61 3 220 8 Pin V cable E46 Power window and interior light
61 3 240 8 Pin V cable E46 Door locks
61 4 350 V cable E38,39,46 Center console switch
61 4 450 20 Pin V cable E30,31,36 LKM and EM convertible top
61 4 460 Set of 4 26 pin cables E31,34,36 Various electrical systems
61 6 020 Set of 6 cables E38 Various electrical systems
61 6 030 Set of 5 cables E38 Various electrical systems
61 6 040 Set of 5 cables E38 Various electrical systems
61 6 050 6 Pin V cable E39,46 Various electrical systems

Important Notes Concerning Airbag Repairs:

Only repair those cables which show visible signs of damage. If there is visible damage, make sure
that only one cable repair is present after repairing. If no visible damage can be identified, the entire
cable must be replaced. When carrying out repairs to the airbag wiring harness use only those parts
specified in the EPC as “Airbag Repair Cable”.

Airbag Repairs Plug Adapter Relay Tester

Part Number Use

61 3 013 Crash Sensor
Always refer to the latest SIB for 61 3 014 Hazard Warning System
information pertaining to the latest 61 3 015 Hazard Warning System C2
Airbag repair procedures. 61 3 017 Changeover Relay
61 3 018 N/O (Normally Open) Relay
61 3 019 Rear Window Heater
61 3 021 Windscreen Heater
SIB 61 02 00 61 3 016 ABS

37
Testing Cables and Breakout Boxes
 NOTES
PAGE
38
Testing Cables and Breakout Boxes