61 13 Special tools for wiring harness repairs

NOTE:

For Special Tool identification, see GENERAL ELECTRICAL SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required:

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

NOTE: Operating instructions for the special tools contained in these repair ranges, refer to manufacture's operating instructions.

Fig 1: Identifying Wiring Harness Repairing Special Tool (1 Of 5)

Courtesy of BMW OF NORTH AMERICA, INC.

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).

Fig 2: Identifying Wiring Harness Repairing Special Tool (2 Of 5)
Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Operating instructions for the special tools contained in the this repair range, refer to manufacture's operating instructions.

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 Wiring Harness Repairing Special Tool (3 Of 5)

Courtesy of BMW OF NORTH AMERICA, INC.

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 Wiring Harness Repairing Special Tool (4 Of 5)

Courtesy of BMW OF NORTH AMERICA, INC.

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 Wiring Harness Repairing Special Tool (5 Of 5)

Courtesy of BMW OF NORTH AMERICA, INC.

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: refer to applicable service information for PLUG CONNECTIONS, TERMINALS, POWER DISTRIBUTION BOX .

Fig 6: Identifying Special Tool Kit (1 Of 3)

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

Handling:

Crimping stop parts (contacts).

Fig 7: Identifying Special Tool Kit (2 Of 3)

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

Cutting to length and stripping insulation from optical fibers. Refer to 61 13 ... CUTTING OFF, STRIPPING INSULATION AND CUTTING OPTICAL FIBRES TO LENGTH .
Crimping optical fibers. Refer to 61 13 ... CRIMPING OPTICAL FIBRES .
Crimping MPQ contacts. Refer to 61 13 ... CRIMPING MICRO POWER QUADLOCK CONTACTS (MPQ) .
Crimping MQS contacts. Refer to 61 13 ... CRIMPING MICRO QUADLOCK SYSTEM CONTACTS (MQS) .

Fig 8: Identifying Special Tool Kit (3 Of 3)
Courtesy of BMW OF NORTH AMERICA, INC.

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

Handling:

Repairing ribbon cables.

Fig 9: Identifying Special Tool For Repairing Ribbon Cable

Courtesy of BMW OF NORTH AMERICA, INC.