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

Special tools required:

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:

Fig 1: Identifying Special Tools Kit

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Special tool 61 9 040

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

Fig 2: Identifying Comb Connector Contact Sleeve

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Alternatively:

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

Fig 3: Identifying Comb Connector Contact Sleeve

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Cut through wire loop in wiring harness at established point.

Strip insulation from both wire ends.

See repair instructions

CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES

Fig 4: Identifying Stripping Tool

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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: Identifying Connector Crimping Parts

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Crimp connecting cable for retrofitting likewise with contact sleeve.

Fig 6: Identifying Crimp Cable

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Cut required number of poles to length for comb connectors.

Fig 7: Identifying Comb Connectors Poles

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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: Identifying Special Tool (61 9 041)

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Unlock special tool 61 9 041 :

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

Or:

Compress handles until limit position, hand pliers unlock automatically.

Fig 9: Pressing Hand Pliers

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

Fig 10: Inserting Comb Connectors In Special Tool (61 9 041)

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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 limit position.

Fig 12: Pressing Hand Pliers

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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: Identifying Connector 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.

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

Fig 14: Identifying Comb Connector Contacts

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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, luggage compartment):

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

Fig 15: Sliding Comb Connector Into Insulation Housing

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