61 13... Crimping end wires

Special tools required: 

• 12 1 080
• 12 1 081
• 12 1 083

1. Crimping contact sleeves for 4 mm ²  comb connectors and ignition cable contacts 

   Use special tool kit 12 1 080 to attach ignition cable contacts and crimp 4 mm² contact sleeves for comb connectors.

   • 12 1 081 (hand pliers)
   • 12 1 083 (nest)

   See repair instructions 

   Special tools for wiring harness repairs.

   Fig 1: Identifying Hand Pliers (12 1 081)

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   Release special tool 12 1 081 :

   Squeeze grips (1) lightly and push release lever (2) in direction of arrow.

   Or:

   Compress handles until limit position, hand pliers unlock automatically.

   Fig 2: Pushing Release Lever

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   Place 4 mm² contact sleeve in nest with anti-twist safeguard (1) as far as possible.

   Fig 3: Locating Contact Sleeve With Anti-Twist Safeguard

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   Preload contact by squeezing matrix in crimping tool. Grip contact (1) firmly only, do not crimp.

   Fig 4: Identifying Grip Contact And Crimping Tool

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   NOTE: Follow procedure for cutting and stripping insulation from cables.

   Insert stripped end of wire (7) in the contact. Ensure insulation and stripped wire end are correctly laid in contact.

   Compress crimping tool to limit position.

   Crimping tool unlocks automatically.

   Take contact out of crimping tool.

   Fig 5: Inserting Stripped End Of Wire In Contact

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2. Checking crimping 

   Check insulation crimping (8) and wire crimp (9) against following illustrations to ensure crimps are correctly located.

   NOTE: Illustration shows butt connectors and contact sleeves for comb connectors knocked on one side. The crimping procedure is identical here.
   Fig 6: Identifying Insulation Crimping And Wire Crimp

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   Correct crimping: 

   Visible conductor end (10).

   Visible insulation end (11).

   Fig 7: Identifying Visible Conductor End And Visible Insulation End

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   Incorrect crimping: 

   Conductor end (10) inserted too far.

   Insulation end (11) in wire crimp.

   If necessary, repeat crimping with a new contact.

   Fig 8: Identifying Conductor End In Wire Crimp Incorrect Position

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   Incorrect crimping: 

   Conductor end (10) not visible.

   Insulation end (11) not visible.

   If necessary, repeat crimping with a new contact.

   Fig 9: Identifying Conductor End Incorrect Position

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