61 13 Special tools for wiring harness repairs

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

Fig 1: Identifying Tools For Repair Range I, II & III

Courtesy of BMW OF NORTH AMERICA, INC.

1. Order No.: 81 24 9 408 080
2. Order No.: 81 24 9 408 300
3. Order No.: 81 24 9 408 400

Sourcing reference: BMW Parts Service.

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 Special Tool For Repair Range IV

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 3: Identifying Special Tool For Cutting And Stripping Wires

Courtesy of BMW OF NORTH AMERICA, INC.

Handling:

Cutting to length and stripping insulating from cables

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.

Fig 4: Identifying Hand Pliers

Courtesy of BMW OF NORTH AMERICA, INC.

Handling:

Crimping stop parts (contacts).

Fan connector for retrofitting/repairs.

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.

Fig 5: Identifying Hand Pliers With Matrix

Courtesy of BMW OF NORTH AMERICA, INC.

Handling:

Antenna elbow plug on radio receiver.

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

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

Fig 6: Identifying Releasing And Pressing-Out Tool

Courtesy of BMW OF NORTH AMERICA, INC.

Handling:

Opening plug housings and removing contacts of different plug systems. Refer to 61 13 ... OPENING PLUG HOUSINGS AND REMOVING CONTACTS OF DIFFERENT PLUG SYSTEMS  .

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

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

Courtesy of BMW OF NORTH AMERICA, INC.

Handling:

Crimping stop parts (contacts).

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

Fig 8: Identifying Crimping Set

Courtesy of BMW OF NORTH AMERICA, INC.

• 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) 

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

Fig 9: Identifying Special Tool

Courtesy of BMW OF NORTH AMERICA, INC.

Handling:

Repairing ribbon cables. Refer to 61 13 ... REPAIRING RIBBON CABLES  .