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

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 Kit

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 2: Identifying Contact Sleeve With Wire Cross-Section

Courtesy of BMW OF NORTH AMERICA, INC.

Alternatively:

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

Fig 3: Identifying Contact Sleeves And 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 Wire Stripper

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 repair instructions:
BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION .

Fig 5: Identifying Crimping On Stop Parts

Courtesy of BMW OF NORTH AMERICA, INC.

Crimp connecting cable for retrofitting likewise with contact sleeve.

Fig 6: Identifying Crimp Connecting Cable With Contact Sleeve

Courtesy of BMW OF NORTH AMERICA, INC.

Cut required number of poles to length for comb connectors.

Fig 7: Identifying 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 Special Tool (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 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: Pressing Hand Pliers And Slide On Contact Sleeve Until 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: Identifying Contact Sleeves And Comb Connector

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.

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.

Fig 14: Identifying Sealing Compound Applying Area On Both Sides And Contacts

Courtesy of BMW OF NORTH AMERICA, INC.

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 Until Locks

Courtesy of BMW OF NORTH AMERICA, INC.