61 13... Installing comb connector for retrofitting/repairs

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2019 MINI Cooper, 2018 MINI Cooper, 2017 MINI Cooper, 2016 MINI Cooper, and 2015 MINI Cooper. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

61 9 041
61 9 042

NOTE: The repair product range IV for vehicle electrical system contains the required special tools and individual parts for retrofitting and repair work with the aid of fan connectors.

The case can no longer be ordered. Order individual parts for wiring harness repair via BMW/MINI parts catalogue.

Fig 1: Special Tools And Individual Parts

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Choose contact sleeve (up to 4 mm2) in accordance with wire cross-section.

Fig 2: Contact Sleeve With Wire Cross-Section

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Alternatively:

Choose contact sleeves (up to 2.5 mm 2) or comb connectors.

Fig 3: Contact Sleeves And Comb Connectors

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Cut through wire loop in wiring harness at established point.

Strip off insulation from both wire ends.

See repair instructions:

CUTTING OFF/STRIPPING INSULATION/CUTTING TO LENGTH

Fig 4: Wire Stripper

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Crimp contact sleeves on both wire ends.

See repair instructions:

CRIMPING ON STOP PARTS

NOTE: If using repair kit for contact sleeves, refer to repair instructions:

BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION .

Fig 5: Crimp Contact Sleeves On Both Wire Ends

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Crimp connecting cable for retrofitting likewise with contact sleeve.

Fig 6: Crimping Connecting Cable With Contact Sleeve

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Cut required number of poles to length for comb connectors.

Fig 7: Comb Connectors And Poles Required Number

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Special tool 61 9 041 (hand pliers) in conjunction with 61 9 042 (matrix) are used for pushing contact sleeves onto comb connectors.

See repair instructions:

SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

Fig 8: Special Tool (Hand Pliers)

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Unlock special tool 61 9 041:

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

Or:

Compress handles up to stop, and hand pliers unlock automatically.

Fig 9: Pushing Release Lever

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Insert prepared comb connectors (3) in special tool 61 9 041/61 9 042.

Fig 10: Inserting Prepared Comb Connectors

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Attach wire with contact sleeve to comb connector.

Fig 11: Attaching Wire With Contact Sleeve To Comb Connector

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Press hand pliers together and slide on contact sleeve until stop.

Fig 12: Pressing Hand Pliers And Slide On Contact Sleeve Until Stop

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IMPORTANT: Once contact sleeves have been pushed on, they should not be detached again from the comb connector or reused.
Push on further contact sleeves for potential branching.

Fig 13: Pushing Further Contact Sleeves

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Installation in wet area (engine compartment, wheel arch):

Apply sealing compound on both sides and press into contacts (1).

Fit heat-shrink tubing and heat up with hot air blower (2) (approx. 250 °C).

NOTE: Ensure that comb connector has sufficient contact surface on attachment point.

Fig 14: Fitting Heat-Shrink Tubing And Hot Air Blower

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Do not heat-shrink tubing on edges of comb connector too strongly, risk of cracking.

Allow heat-shrink tubing to cool down until hand-warm. Then press sealing material again into contacts and onto edges of comb connector.

If necessary, carefully heat-shrink tubing again.

Installation in dry area (interior, trunk):

Slide assembled comb connector into insulation housing until it locks into place.

Fig 15: Sliding Assembled Comb Connector Into Insulation Housing Until Locks

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