Cutting to length and strip off insulation from cables (all 7' series models 2016-2022)

Special tools required:

12 1 080
12 1 081
12 1 083
2 221 122
0 494 159
0 496 849
0 496 833
2 407 379
61 4 320
61 4 340
61 0 210
61 0 220
61 0 230

Spare parts for vehicle electronics (housing and contacts):

Situation:
- The individual special tools numbers from "Repair set 4 for vehicle electrical system" are no longer available from Cartool.
- With immediate effect, all spare parts from "Repair set 4 for vehicle electrical system" (e.g. repair sets "A" to "N" with special tools number 61 9 050 and 61 9 06x) can be ordered from the BMW Parts Service.
- Proceed as follows to ensure correct assignment or recoding of the special tools number concerned to the BMW part number .
Procedure:
- Orders for spare parts from "Repair set 4 for vehicle electrical system" should only be placed with the BMW Parts Service.

For cutting cables to length and strip off insulation, use the insulation strippers 2 221 122 .

Stripped length:

Wire cross-section (mm² )	Stripped length (mm)
0.35... 0.50	4.0
0.75... 1.00	4.5
1.00... 2.50	5.0

Crimping of Nano MQS stops (only G11; G12)
Crimping of NANO MQS CONTACTS (MQS).
- Special tool handle 0 494 159 or 0 496 849
- Special tool die-plate 0 496 833
- Stripping tool 2 407 379
Crimping of stops up to 2.5 mm ²
Crimping Micro Quadlock System contacts (MQS).
- Special tool 61 4 320
Crimping Micro Power Quadlock contacts (MPQ).
- Special tool 61 4 320
Crimping miscellaneous stop parts up to 2.5 mm²
- Special tool 61 4 340
Crimping of stops above 2.5 mm ²
Crimping load current contacts (LSK 8).
- Special tool 61 0 210
Crimping load current contact 2.8.
- Special tool 61 0 220
Crimping double spring contact (DFK 40)

Crimping MAK 8
- Special tool 61 0 230
Crimp the impact connectors and contact sleeves for comb connectors from 2.5 mm ²
Refer to Service Information:

New universal crimping die
- Situation:
  - The variety of contacts and therefore also the various crimping types always require a new crimping tool. To save costs, a universal crimping die was developed. This universal crimping die can crimp a large number of contacts fitted in the vehicles.The wire cross section can vary between 0.35 and 2.5 mm² . Specifications for crimping the individual contacts are always met.
  - The new universal crimping die is used in conjunction with the special tool 61 4 321 (handle without crimping die) and stored in the special tool case 61 4 320.
  - Enclosure 1 : Setup and storage location of the universal crimping die
  - Enclosure 2 : General information about use of the special tool
- Procedure:
  - Offer tools will be sent to every dealer with a tools agreement.
Crimp the impact connectors and contact sleeves for comb connectors from 2.5 mm ²
Refer to Service Information:

NEW CRIMPING PLIERS AND INTERCHANGEABLE DIES ALL .
Crimping contact sleeves for 4 mm ² comb connectors and ignition cable contacts
Use special tool kit 12 1 080 to attach ignition cable contacts and crimp 4 mm² contact sleeves for comb connectors.
- 12 1 081 (hand pliers)
- 12 1 083 (nest)
See repair instructions

SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

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Unlock special tool 12 1 081 :

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

Or:

Compress handles up to stop, and hand pliers unlock automatically.

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Place 4 mm² contact sleeve in nest with anti-twist lock (1) as far as possible.

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Preload contact by squeezing matrix in crimping tool. Grip contact (1) firmly only, do not crimp.

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NOTE: Follow procedure for cutting and stripping off insulation from cables.

Insert stripped end of wire (7) in the contact. Ensure insulation and stripped wire end are correctly placed in contact.

Compress crimping tool up to stop.

Crimping tool unlocks automatically.

Take contact out of crimping tool.

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Checking crimping
Check insulation crimping (8) and wire crimp (9) against following illustrations to ensure crimps are correctly located.

NOTE: Illustration shows butt connectors and contact sleeves for comb connectors knocked on one side. The crimping procedure is identical here.

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Correct crimping:

Visible conductor end (10).

Visible insulation end (11).

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Incorrect crimping:

Conductor end (10) inserted too far.

Insulation end (11) in wire crimp.

If necessary, repeat crimping with a new contact.

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Incorrect crimping:

Conductor end (10) not visible.

Insulation end (11) not visible.

If necessary, repeat crimping with a new contact.

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Insulate the crimping point with the heat-shrink tubing

Push the heat-shrink tubing (8) onto the free wire end before crimping.

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Crimp unused wire end using butt connector.

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Position the heat-shrink tubing centrally over the butt connector.

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Attention!

Do not combustion shrink-on sleeve.

Mount the solder shrink reflector on the hot air blower.

Shrink the heat-shrink tubing at 400°C using a hot-air blow blower until adhesive is visibly emerging evenly on both sides (9) of the heat-shrink tubing.

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