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

Special tools required:

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.
The case can no longer be ordered. Order individual parts for wiring harness repair through BMW Parts Department.

Fig 1: Identifying Special Tools For Wiring Harness Repairs

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

Fig 2: Identifying Contact Sleeves

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Alternatively:

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

Fig 3: Identifying Comb Connectors Contact Sleeves

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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 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: Identifying Contact Sleeves

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Crimp connecting cable for retrofitting likewise with contact sleeve.

Fig 6: Identifying Connecting Cable With Contact Sleeve

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Cut required number of poles to length for comb connectors.

Fig 7: Identifying Comb Connectors

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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 Hand Pliers In Conjunction With Matrix

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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: Pushing Release Lever Using Special Tool

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

Fig 10: Inserting Prepared Comb Connectors In Special Tool

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Attach wire with contact sleeve to comb connector.

Fig 11: Connecting 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: Identifying Contact Sleeve Limiting Position

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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 Contact Sleeve On Comb Connector

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