Special tools for wiring harness repairs (all 7' series models 2016-2022)

Special tools required:

61 0 300
61 0 400
61 1 100
61 4 320
61 0 200
61 0 210

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61 0 220
61 0 230
61 0 240

Courtesy of BMW OF NORTH AMERICA, INC.

Courtesy of BMW OF NORTH AMERICA, INC.

Wiring harness repair kit 4.0 (61 13 4 470 939) and associated special tools

The applicable BMW parts catalogue offers a repair kit for repairing wiring harnesses

In addition to the various bushing housings, butt connectors (with heat-shrink tubing) and bushing contacts with cables, this kit also includes storage space for existing special tools.

Wiring harness repair kit 4.0

(61 13 2 470 939)

Scope of delivery:

Item 1 (filled) kit boxes for repair lines with and without single conductor seal
Item 2 (filled) kit boxes for the bushing housings
Item 3 (empty) kit box (61 13 5 A09 485 ) for existing release tools
Item 4 (empty) kit box (61 13 5 A09 476 ) for existing special tools for wiring harness repairs

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NOTE: A card is enclosed to help better assign and identify the bushing housings. It contains information on the bushing contacts with cables (repair cables) and the release tools for the secondary and primary locking devices. There are contact bushings for which both locking forms are not relevant.

Printed circuit board for bushing housing

Item A front of card
Item B rear of card
Item 1 BMW order number for bushing housing
Item 2 QR code
Item 3 BMW order number for release tool
Item 4 BMW order number for contact bushing with cable

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NOTE: By scanning the QR code, the user is directly connected to the manufacturer's website and the following information is quickly displayed:

Illustration of bushing housing
Bushing housing can be rotated 360°
Associated release tools
A table with technical information on the bushing housing (type, number of poles, color etc.)
How-to-use video for the release tools (to download)

List of the special tools for the wiring harness repair kit 4.0

The special tools listed below are not included in the scope of delivery of the wiring harness repair kit 4.0 and may already be available or must be ordered separately.

For these special tools, both empty kit boxes (61 13 5 A09 476 and 61 13 5 A09 485 ) are included in the scope of delivery of the wiring harness repair kit 4.0.

Overview of the special tools for wiring harness repairs

Empty kit box (61 13 5 A09 476 ) for existing special tools for wiring harness repairs.

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Order number	Description
83 30 2 467 488	Die (0.13 - 0.5 mm² and 0.5 - 1.5 mm² )
83 30 2 467 489	Die (1.5-2.5 mm² )
83 30 2 467 490	Die (3.5-6.0 mm² )
83 30 2 467 417	Gas soldering iron
83 30 0 494159	Handle (optional for 83 30 0 496 849 )
83 30 0 496 849	Handle (optional for 83 30 0 494 159 )
83 30 2 407 379	Stripping tool for cable diameters 0.13 0.13 - 0.5 mm
83 30 2 221 122	Pliers (stripping pliers) for cable diameters 0.5 mm and higher

Overview of the release tools and the relevant information

Empty kit box (61 13 5 A09 485) for existing release tools.

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Special tool number	Order number	Description	Information bulletins
61 0 303	83 30 0 495 385	Release tool	02 05 05 (217)
61 0 312	83 30 0 495 394	Release tool
61 0 314	83 30 0 495 396	Release tool
61 0 316	83 30 0 495 398	Release tool
61 0 317	83 30 0 495 399	Release tool
61 0 322	83 30 0 495 404	Release tool
61 0 324	83 30 0 495 406	Release tool
61 0 325	83 30 0 495 578	Release tool	02 05 06 (294)
61 0 326	83 30 0 496676	Release tool	02 05 06 (294)
61 0 332	83 30 0 496 332	Release tool	02 03 08 (440)
61 0 333	83 30 0 496 333	Release tool	02 03 08 (440)
83 30 2 471 325		Release tool	02 02 19 (626)
83 30 2 471 326	Release tool
83 30 2 471 327	Release tool
83 30 2 471 328	Release tool
83 30 2 471 329	Release tool
83 30 2 471 330	Release tool
83 30 2 471 331	Release tool
83 30 2 471 332	Release tool
83 30 2 471 333	Release tool

NOTE: There is an existing tool set for the HF contacts (RTK031).

Order number HF contacts	Description	Special tool number Tool set	Order number Tool set	Description	Information bulletins
61 13 6 918332	H F contact bushing	61 4 280	83 30 0 496 880	Crimping tool	02 02 10 (622)
61 13 6 918333	HF pin contact
61 13 6 918 294	H F contact bushing, angled
61 13 6 931 431	HF pin contact, angled

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Repair product range, vehicle electrical system:

Single parts for wiring harness repairs*

* Sourcing reference: BMW Parts Department

NOTE:

Refer to Service Information:

Recoding of spare parts (housings and contacts) from "Repair set 4 for vehicleelectrical system"

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.

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Release and press-out tool:

Special tool 61 0 300
Special tool 61 0 400 (MINI N12/N14)
Special tool 61 1 100 (combustion engine)

Handling:

UNLOCKING AND DISCONNECTING DIFFERENT PLUG CONNECTIONS , or UNLOCKING AND DISCONNECTING VARIOUS PLUG CONNECTIONS IN ELECTRICAL AND HYBRID VEHICLES .

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Cutting to length and strip off insulation from cables:

Wire stripper MultiStrip10*

*Sourcing reference BMW applicable BMW Workshop Equipment CATALOG .

Handling:

Cutting cables to length and stripping off insulation

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Crimping stop parts (small contacts) and butt connectors:

Special tool 61 4 320

Tool without crimping head
Crimping head (STRIP OFF INSULATION AND CUTTING FIBER-OPTIC CABLES TO LENGTH )
Crimping head (crimping fiber-optic cable contacts)
Crimping head (CRIMPING MQS CONTACTS) .
Crimping head (CRIMPING MPQ CONTACTS) .
Replacement blade (face-cutting fiber-optic cables)
Replacement blade with tool (insulation stripping unit)
Universal crimping head
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.

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Crimping stop parts (large contacts) and butt connectors:

Special tool 61 0 200 (crimping kit)
Special tool 61 0 210 (matrix set SLK 8)
Special tool 61 0 220 (matrix set SLK 2.8)
Special tool 61 0 230 (matrix set MAK 8/DFK4)
Special tool 61 0 240 (butt connector 4.0 - 6.0 mm² )

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Handling:

Refer to Service Information:

NEW CRIMPING PLIERS AND INTERCHANGEABLE DIES ALL .