61 13 Installing fan connector for retrofitting/repairs

Fig 1: Identifying Special Tool 61 9 020

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Refer to repair instructions: 

61 13 SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

Choose contact sleeve (up to 4 mm² ) in accordance with wire cross-section.

Fig 2: Choosing Contact Sleeve (Up To 4 MM2)

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Alternatively:

Choose repair kit A for contact sleeves (up to 2.5 mm² ) for fan connectors.

Fig 3: Identifying Kit A

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Cut through wire loop (1) in wiring harness at determined point (2) with special tool 61 9 043.

Fig 4: Cutting Through Wire Loop (1) In Wiring Harness At Determined Point (2)

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Strip insulation from both wire ends.

Refer to repair instructions: 

61 13 CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES .

Crimp contact sleeves on both wire ends.

Fig 5: Crimping Contact Sleeves On Both Wire Ends

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Refer to repair instructions: 

61 13 CRIMPING ON STOP PARTS 

Crimp connecting cable for retrofitting likewise with contact sleeve.

Fig 6: Crimping Connecting Cable For Retrofitting Likewise With Contact Sleeve

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Take fan connectors from repair range IV for vehicle electrical system 61 9 020 and cut required number of cores to length.

Fig 7: Identifying Fan Connectors

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The special tool 61 9 041 (crimping tool) in conjunction with 61 9 042 (matrix) are used for pushing contact sleeves onto fan connectors.

Fig 8: Identifying Special Tool 61 9 041 (Crimping Tool)

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Refer to repair instructions: 

61 13 SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

Unlock special tool 61 9 041: 

Squeeze grips (1) lightly and push unlocking lever (2) in direction of arrow.

Fig 9: Squeezing Grips (1) Lightly And Pushing Unlocking Lever (2) In Direction Of Arrow

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OR:

Compress handles as far as they will go, tool unlocks automatically.

Insert prepared fan connector (3) in special tool 61 9 041/61 9 042.

Fig 10: Inserting Prepared Fan Connector (3) In Special Tool 61 9 041/61 9 042

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Attach wire with contact sleeve to fan connector.

Fig 11: Attaching Wire With Contact Sleeve To Fan Connector

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Press crimping tool together and slide contact sleeve firmly home.

Fig 12: Pressing Crimping Tool Together And Sliding Contact Sleeve Firmly Home

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Push on further contact sleeves for potential branching.

Fig 13: Pushing On Further Contact Sleeves For Potential Branching

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Installation in wet area (engine compartment, wheel arch): 

Apply sealing compound on both sides and press into contacts (1).

Fit shrink-fit hose and heat up with hot air blower (approx. 250°C) (2).

Fig 14: Identifying Sealing Compound (1) And Shrink-Fit Hose (2)

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Do not heat shrink-fit hose on edges of fan connector too strongly, risk of cracking.

Allow shrink-fit hose to cool down until hand-warm. Then press sealing material again into contacts and onto edges of fan connector.

If necessary, carefully heat shrink-fit hose again.

Installation in dry area (interior, luggage compartment): 

Slide assembled fan connector into insulation housing until it locks into place.

Fig 15: Sliding Assembled Fan Connector Into Insulation Housing Until It Locks Into Place

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