Special tools required:

WARNING: This page is about a different car, the 2003 BMW 525i, 2002 BMW 525i, and 2001 BMW 525i. However, it is still accessible from the selected car via links, so may be relevant.

61 1 150
61 1 190
61 4 320
61 8 084
61 9 020
61 9 029
61 9 041
61 9 042
61 9 043
61 9 044

Repair ranges I, II, III for vehicle electrical system

Order No.: 81 24 9 408 080
Order No.: 81 24 9 408 300
Order No.: 81 24 9 408 400

Sourcing reference: BMW Parts Service.

NOTE: Operating instructions for the special tools contained in these repair ranges, refer to "Tool for wiring harness repair, repair range I, II, III", special tool 61 8 084. See Fig 1.

Fig 1: Identifying Special Tool 61 8 084 (Repair Ranges I, II, III For Vehicle Electrical System)

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Repair range IV for vehicle electrical system, special tool 61 9 020:

Contents:

Special tool 61 9 041 (hand pliers)
Special tool 61 9 042 (matrix)
Special tool 61 9 043 (wire stripper)
Special tool 61 9 044 (matrix)

NOTE: Operating instructions for the special tools contained in the this repair range, refer to "repair range IV for vehicle electrical system (Vol. 1 / Vol. 2 / Vol. 3 / Vol. 4)", special tool 61 9 029. See Fig 2.

Fig 2: Identifying Special Tool 61 9 029 (Repair Range IV For Vehicle Electrical System)

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Special tool 61 9 043 (wire stripper with wire cutter) for cutting and stripping wires.

Handling:

Cutting to length and stripping insulating from cables

Fig 3: Identifying Special Tool 61 9 043 (Wire Stripper With Wire Cutter) For Cutting & Stripping Wires

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Special tool 61 9 041 (hand pliers) with special tool 61 9 042 (matrix) for crimping connectors and contact tubes for fan connectors up to a wire cross-section of 2.5 mm² and for pushing on contact tubes for fan connectors.

Handling:

Crimping stop parts (contacts).

Fan connector for retrofitting/repairs.

Fig 4: Identifying Special Tool 61 9 041 (Hand Pliers) With Special Tool 61 9 042 (Matrix)

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Special tool 61 9 041 (hand pliers) with special tool 61 9 044 (matrix) for crimping cable guide and strain relief device on antenna elbow plug.

Handling:

Antenna elbow plug on radio receiver.

Fig 5: Identifying Special Tool 61 9 041 (Hand Pliers) With Special Tool 61 9 044 (Matrix)

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Special tool 61 1 150 (release and pressing-out tool) for:

releasing round plug housings
releasing relay carriers
pressing out contacts
removing indicator lights

Handling:

Opening plug housings and removing contacts of different plug systems

Fig 6: Identifying Special Tool 61 1 150 (Release & Pressing-Out Tool)

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Repair kit for ignition cables and for crimping fan connector receptacles 4 mm²

Handling:

Crimping stop parts (contacts).

Service Information 1 03 89 (037)

Fig 7: Identifying Repair Kit For Ignition Cables & For Crimping Fan Connector Receptacles

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Special tool 61 4 320 (crimping set with pliers) for:

Cutting to length and stripping insulation from optical fibers
Crimping optical fibers
Crimping MPQ contacts
Crimping MQS contacts

Fig 8: Identifying Special Tool 61 4 320 (Crimping Set With Pliers)

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Special tool 61 1 190 pliers for insulation displacement connector for repairing ribbon cables.

Handling:

Repairing ribbon cables.

Fig 9: Identifying Special Tool 61 1 190 Pliers For Insulation Displacement Connector For Repairing Ribbon Cables

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