Special Tools For Wiring Harness Repairs

Repair ranges I, II, III for vehicle electrical system

I Order No.: 81 24 9 408 080

II Order No.: 81 24 9 408 300

III Order No.: 81 24 9 408 400

Sourcing reference: BMW Parts Service.

Fig 1: Identifying Special Tool Kit 61 8 084 (Repair Ranges I, II, III For Vehicle Electrical System)

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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 Kit 61 9 020 (Repair Range IV For Vehicle Electrical System)

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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 Special Tool 61 9 043 (Wire Stripper With Wire Cutter) For Cutting And Stripping Wires

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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 Special Tool 61 9 041 (Hand Pliers) With Special Tool 61 9 042 (Matrix) For Crimping Connectors And Contact Tubes

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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 Special Tool 61 9 041 With Special Tool 61 9 044 For Crimping Cable Guide And Strain Relief Device On Antenna Elbow Plug

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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

Fig 6: Identifying Special Tool 61 1 150 Release And Pressing-Out Tool

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

Handling:

Crimping stop parts (contacts).

Service Information 1 03 89 (037)

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

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

• Cutting to length and stripping insulation from optical fibers
• Crimping optical fibers
• Crimping MPQ contacts
• Crimping MQS contacts

Fig 8: Identifying Special Tool 61 4 320 (Crimping Set With Pliers)

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

Handling:

Repairing ribbon cables.

Fig 9: Identifying Special Tool 61 1 190 Ribbon Cable Pliers

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