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

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 Vehicle Electrical System Repairing

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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 mm 2) or comb connectors.

Fig 3: Identifying Contact Sleeves And Comb Connectors

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Cut through wire loop in wiring harness at established point.

Strip insulation from both wire ends.

See repair instructions in:

CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES

Fig 4: Identifying Crimp Tool

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Crimp contact sleeves on both wire ends.

See repair instructions in:

CRIMPING ON STOP PARTS

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

BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION .

Fig 5: Identifying Crimp Contact Sleeves On Wire End

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Crimp connecting cable for retrofitting likewise with contact sleeve.

Fig 6: Identifying Crimp Connecting Cable For Retrofitting

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Cut required number of poles to length for comb connectors.

Fig 7: Identifying 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 in:

SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

Fig 8: Identifying Special Tool 61 9 041 (Hand Crimping Tool)

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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

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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 / 61 9 042)

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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 Contact Sleeve Using 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 Contact Sleeve On Comb Connector

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