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

Special tools required:

61 9 041
61 9 042

NOTE: The repair product range IV for vehicle electrical system contains 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 via the applicable BMW parts catalogue.

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

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Alternatively:

Choose contact sleeves (up to 2.5 mm² ) or comb connectors.

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Cut through wire loop in wiring harness at established point.

Strip off insulation from both wire ends.

See repair instructions:

CUTTING CABLES TO LENGTH AND STRIPPING OFF INSULATION

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Crimp contact sleeves on both wire ends.

See repair instructions:

For crimping on stop parts, refer to CUTTING CABLES TO LENGTH AND STRIPPING OFF INSULATION .

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

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Crimp connecting cable for retrofitting likewise with contact sleeve.

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Cut required number of poles to length for comb connectors.

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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:

SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

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Unlock special tool 61 9 041:

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

Or:

Compress handles up to stop, and hand pliers unlock automatically.

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

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Attach wire with contact sleeve to comb connector.

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Press hand pliers together and slide on contact sleeve until stop.

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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.

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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.

Installation in dry area (interior, trunk):

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Slide assembled comb connector into insulation housing until it locks into place.

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