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

Special tools required:

61 9 040 . See GENERAL ELECTRICAL SYSTEM - SPECIAL TOOLS .
61 9 041
61 9 042

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

Special tools:

special tool 61 9 040

Fig 1: Identifying Special Tool Kit
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Choose contact sleeve (up to 4 mm² ) in accordance with wire cross-section.

Fig 2: Identifying Contact Sleeve

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Alternatively:

Choose contact sleeves (up to 2.5 mm² ) for fan connectors.

Fig 3: Identifying Contact Sleeves

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Cut through wire loop in wiring harness at established point.

Strip insulation from both wire ends.

Refer to repair instructions:

Cutting to length and stripping insulation from cables

Fig 4: Identifying Special Tool

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Crimp contact sleeves on both wire ends.

Refer to repair instructions:

Crimping on stop parts

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

Butt connector for repairing a plug connection.

Fig 5: Identifying Contact Sleeves

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Crimp connecting cable for retrofitting likewise with contact sleeve.

Fig 6: Identifying Crimp Connecting Cable

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Cut required number of poles to length for fan connectors.

Fig 7: Identifying Number Of Poles

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

Refer to repair instructions:

Special tools for wiring harness repairs.

Fig 8: Identifying Special Tools

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Unlock special tool 61 9 041:

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 9: Identifying Grips And Unlocking Lever

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Insert prepared fan connector (3) in special tool 61 9 041 / 61 9 042.

Fig 10: Identifying Fan Connector

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Attach wire with contact sleeve to fan connector.

Fig 11: Attaching Wire With Contact Sleeve

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Press crimping tool together and slide contact sleeve firmly home.

Fig 12: Pressing Crimping Tool Together

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IMPORTANT: Once contact sleeves have been pushed on, they should not be detached again from the fan connector or reused.

Push on further contact sleeves for potential branching.

Fig 13: Pushing On 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 shrink-fit hose and heat up with hot air blower (2) (approx. 250°C).

Fig 14: Installing Shrink-Fit Hose

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NOTE: Ensure that fan connector has sufficient contact surface on mounting point.

Do not heat shrink-fit hose on edges of fan connector too strongly, risk of cracking.

Allow shrink-fit hose to cool down until hand-warm. Then press sealing material again into contacts and onto edges of fan connector.

If necessary, carefully heat shrink-fit hose again.

Installation in dry area (interior, luggage compartment):

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

Fig 15: Sliding Assembled Fan Connector Into Insulation Housing

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