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

Special tools:

Special tool 61 9 040

Fig 1: Identifying Special Tools (61 9 040)
Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 2: Identifying Contact Sleeves

Courtesy of BMW OF NORTH AMERICA, INC.

Alternatively:

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

Fig 3: Identifying Contact Sleeves For Comb Connectors

Courtesy of BMW OF NORTH AMERICA, INC.

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 Cutting/Stripping Tool

Courtesy of BMW OF NORTH AMERICA, INC.

Crimp contact sleeves on both wire ends.

See repair instructions:

CRIMPING ON STOP PARTS

NOTE: If using repair kit for contact sleeves, refer to:
BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION .

Fig 5: Crimping Contact Sleeves On Both Wire Ends

Courtesy of BMW OF NORTH AMERICA, INC.

Crimp connecting cable for retrofitting likewise with contact sleeve.

Fig 6: Crimping Connecting Cable For Retrofitting Likewise With Contact Sleeve

Courtesy of BMW OF NORTH AMERICA, INC.

Cut required number of poles to length for comb connectors.

Fig 7: Cutting Required Number Of Poles To Length For Comb Connectors

Courtesy of BMW OF NORTH AMERICA, INC.

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

Courtesy of BMW OF NORTH AMERICA, INC.

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

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 10: Inserting Prepared Comb Connectors In Special Tool

Courtesy of BMW OF NORTH AMERICA, INC.

Attach wire with contact sleeve to comb connector.

Fig 11: Attaching Wire With Contact Sleeve To Comb Connector

Courtesy of BMW OF NORTH AMERICA, INC.

Press hand pliers together and slide on contact sleeve until limit position.

Fig 12: Sliding Contact Sleeve Up To Limit Position

Courtesy of BMW OF NORTH AMERICA, INC.

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-On Contact Sleeves

Courtesy of BMW OF NORTH AMERICA, INC.

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: Applying Sealing Compound And Fitting Heat-Shrink Tubing

Courtesy of BMW OF NORTH AMERICA, INC.

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 Assembled Comb Connector Into Insulation Housing

Courtesy of BMW OF NORTH AMERICA, INC.