61 13... Installing comb connector for retrofitting/repairs: Notes

WARNING: This page is about a different variant/trim than selected.

Special tools required:

NOTE: The repair range IV for vehicle electrical system contained the required special tools and individual parts for retrofitting and repair work with the aid of fan connectors.
The case can no longer be ordered. Order individual parts for wiring harness repair through BMW Parts Department.

Special tools:

Special tool 61 9 040

Fig 1: Identifying Special Tool (SI 02 04 07 341)
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Choose contact sleeve (up to 4 mm² ) in accordance with wire cross-section.

Fig 2: Identifying Contact Sleeve Dimensions

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Alternatively:

Choose contact sleeves (up to 2.5 mm ² ) for comb connectors.

Fig 3: Identifying Contact Sleeves For Comb Connectors

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Cut through wire loop in wiring harness at established point.

Strip insulation from both wire ends.

See repair instructions

CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES

Fig 4: Cutting Through Wire Loop In Wiring Harness At Established Point

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Crimp contact sleeves on both wire ends.

See repair instructions

CRIMPING ON STOP PARTS

NOTE: If using repair kit for contact sleeves, refer to appropriate repair instructions:

BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION .

Fig 5: Identifying Crimping Repair Kit

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Crimp connecting cable for retrofitting likewise with contact sleeve.

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

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Cut required number of poles to length for comb connectors.

Fig 7: Cutting Required Number Of Poles To Length For Comb Connectors

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Special tool 61 9 041 (hand pliers) in conjunction with 61 9 042 (matrix) are used for pushing contact sleeves onto comb connectors.

See repair instructions

SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

Fig 8: Identifying Special Tool (61 9 041)

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Unlock special tool 61 9 041 :

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

Or:

Compress handles until limit position, hand pliers unlock automatically.

Fig 9: Squeezing Grips Lightly And Push Release Lever

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Insert prepared comb connectors (3) in special tool 61 9 041 /61 9 042 .

Fig 10: Inserting Prepared Comb Connectors In Special Tool

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Attach wire with contact sleeve to comb connector.

Fig 11: Attaching Wire With Contact Sleeve To Comb Connector

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Press hand pliers together and slide on contact sleeve until limit position.

Fig 12: Pressing Hand Pliers And Slide On Contact Sleeve Until Limit Position

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IMPORTANT: Once contact sleeves have been pushed on, they should not be detached again from the comb connector or reused.

Push on further contact sleeves for potential branching.

Fig 13: Pushing On Further Contact Sleeves For Potential Branching

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