April 5, 2026: LEMON Manuals is launched! Read the announcement.

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

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:

Fig 1: Identifying Special Tools For Wiring Harness Repairs

G08530381

Courtesy of BMW OF NORTH AMERICA, INC.

Special tool 61 9 040

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

Fig 2: Identifying Contact Sleeves

G08530382

Courtesy of BMW OF NORTH AMERICA, INC.

Alternatively:

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

Fig 3: Identifying Comb Connectors And Contact Sleeves

G08530383

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 Crimp Tool

G08530384

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 Crimp Contact Sleeves On Wire End

G08530385

Courtesy of BMW OF NORTH AMERICA, INC.

Crimp connecting cable for retrofitting likewise with contact sleeve.

Fig 6: Identifying Crimp Connecting Cable For Retrofitting

G08530386

Courtesy of BMW OF NORTH AMERICA, INC.

Cut required number of poles to length for comb connectors.

Fig 7: Identifying Poles

G08530387

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 61 9 041 (Hand Crimping Tool)

G08530388

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

G08530389

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

G08530390

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

G08530391

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 12: Pressing Contact Sleeve Using Hand Pliers

G08530392

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 Sleeve On Comb Connector

G08530393

Courtesy of BMW OF NORTH AMERICA, INC.