61 11... Fitting repair kit for positive battery lead transfer point

Special tools required: 

• 32 2 040

Repair instructions describe fitting of repair kit for positive battery lead transfer point (part number 9 321 691).

READ AND COMPLY WITH NOTES ON HANDLING WIRING HARNESSES AND WIRING !

Necessary preliminary tasks: 

REMOVE REAR RIGHT WHEEL ARCH TRIM Remove battery

Work is shown on the E91 by way of example.

There may be differences in detail in the case of other vehicle types and equipment specifications.

Figure shows the following lines (2):

• Left: positive battery lead for VVT (thinner lead)
• Right side: positive battery lead (thicker lead)
  Fig 1: Identifying Positive Battery Leads

  Courtesy of BMW OF NORTH AMERICA, INC.

Only remove positive battery lead on the right! 

Unclip the right-hand cover (1) and undo the nut beneath it (tightening torque 8 Nm).

Remove right-hand positive battery lead (2).

Twist right-hand clamp ring (1) in direction of arrow and remove.

Installation note: 

Ensure that the tension rings (1) are correctly seated.

Position suitable grips (2) on plastic body (3) as shown.

Firmly hold plastic body (3) with grips (2).

Unscrew sleeve (4) with spanner (1).

If sleeve (4) is damaged such that it cannot be unscrewed: 

Position grips (1 and 2) as shown, break plastic body (3) by twisting the two pairs of grips (1 and 2) in opposite directions and remove.

Unscrew sleeve (4) with grips (1).

Screw nut (1) onto stud (2) and position special tool 32 2 040 as shown.

With the aid of special tool 32 2 040, press stud (2) through until stud (2) splits open plastic housing (3).

Pull stud (2) out of plastic housing (3).

Remove shrink-fit hose (1) in area marked by arrow.

Clamp mole grips on positive battery lead terminal (4) as shown.

Grip plastic cap (1) with suitable pliers (2) as illustrated.

Bracing pliers (2) against clamped mole grips (3), pull plastic cap (1) off positive battery lead terminal (4) with pliers (2).

Clean positive battery lead terminal (1) with wire brush on both sides.

Remove any residues such as indicated by arrows.

Clean positive battery lead terminal (1) and positive battery lead insulation in marked area (2).

Before parts from the repair kit are fitted, the type of positive battery lead terminal must be established.

Compare shape of battery positive lead terminal on vehicle with the following pictures and identify which type it is: 

1. Aluminium lead
2. Copper lead

Casing (1) and grommet (3) carry an identification mark (2):

• For aluminium lead, use casing (1) and grommet (3) marked "Al"  .
• For copper lead, use casing (1) and grommet (3) marked "Cu"  .
Fig 9: Identifying Aluminium Lead, Copper Lead, Casing, Grommet, And Identification Mark
Courtesy of BMW OF NORTH AMERICA, INC.

1. Slide grommet (2) from repair kit onto positive battery lead (1).
2. Slide plastic body (3) from repair kit onto positive battery lead terminal (1).
3. Fit stud (4) from repair kit.
4. Screw sleeve (5) from repair kit onto stud (4) and tighten.
5. Position grommet (2) on plastic body (3) as shown.
Fig 10: Identifying Positive Battery Lead, Grommet, Plastic Body, Stud, And Sleeve
Courtesy of BMW OF NORTH AMERICA, INC.

Insert 38 mm dia. seal (1) from repair kit at marked position on plastic body (2).

Fit 23 mm dia. seal (3) from repair kit on plug bolt (4) from repair kit.

Screw plug bolt (4) and seal (3) into plastic body (2) in marked position.

Clean bodywork in area of sealing face.

Fit positive battery lead to transfer point.