61 13 Crimping Stop Parts

Special tools required: 

• 12 1 080 
• 12 1 081 
• 12 1 083 

(see ENGINE ELECTRICAL SYSTEM - SPECIAL TOOLS )

1. Crimping butt connectors and contact sleeves for fan connectors up to 2.5 mm ²  . Refer to  BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION  . 
2. Crimping butt connectors and contact sleeves for fan connectors from 2.5 mm ² 
3. Crimping contact sleeves for fan connectors 4 mm 2 and ignition cable contacts 

   Special tool kit 12 1 080  is used to fit ignition cable contacts and to crimp 4 mm² contact sleeves for fan connectors.

   • 12 1 081  (hand crimping tool)
   • 12 1 083  (matrix)

   Refer to repair instructions: 

   SPECIAL TOOLS FOR WIRING HARNESS REPAIRS 

   Fig 1: Identifying Special Tools (12 1 081) And (12 1 083)

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   Unlock special tool 12 1 081  :

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

   Or:

   Compress handles as far as they will go, tool unlocks automatically.

   Fig 2: Squeezing Grips

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   Insert contact sleeve 4 mm 2 in nest with lock (1) as far as it will go.

   Fig 3: Identifying Contact Sleeve Lock

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

   Fig 4: Identifying Grip Contact Of Plier

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

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

   Compress crimping tool as far as it will go.

   Crimping tool unlocks automatically.

   Take contact out of crimping tool.

   Fig 5: Identifying Stripped End Of Wire

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4. Checking crimping 

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

   NOTE: Illustration shows butt connectors and contact sleeves for fan connectors knocked on one side. The crimping procedure is identical here.
   Fig 6: Identifying Insulation Crimp And Wire Crimp

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   Correct crimping: 

   Visible conductor end (10).

   Visible insulation end (11).

   Fig 7: Identifying Correct Crimping

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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.

   Fig 8: Identifying Incorrect Crimping

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   Incorrect crimping: 

   Conductor end (10) not visible.

   Insulation end (11) not visible.

   If necessary, repeat crimping with a new contact.

   Fig 9: Identifying Incorrect Crimping

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