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

Special tools required:

61 9 040
61 9 041
61 9 042 . See GENERAL ELECTRICAL SYSTEM - SPECIAL TOOLS -- CLUBMAN .

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 Service.

Special tools:

special tool 61 9 040

Fig 1: Identifying Special Tool 61 9 040
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

Courtesy of BMW OF NORTH AMERICA, INC.

Alternatively:

Choose contact sleeves (up to 2.5 mm² ) for fan connectors.

Fig 3: Identifying Contact Sleeves For Fan Connectors

Courtesy of BMW OF NORTH AMERICA, INC.

Cut through wire loop in wiring harness at established point.

Strip insulation from both wire ends.

Refer to repair instructions:

Cutting to length and stripping insulation from cables

Fig 4: Identifying Plier

Courtesy of BMW OF NORTH AMERICA, INC.

Crimp contact sleeves on both wire ends.

Refer to repair instructions:

Crimping on stop parts:

NOTE: If using repair kit for contact sleeves, refer to repair instructions for Butt connector for repairing a plug connection

Fig 5: Crimping Contact Sleeves On Both Wire Ends

Courtesy of BMW OF NORTH AMERICA, INC.

Crimp connecting cable for retrofitting likewise with contact sleeve.

Fig 6: Crimping Connecting Cable For Retrofitting Likewise

Courtesy of BMW OF NORTH AMERICA, INC.

Cut required number of poles to length for fan connectors.

Fig 7: Identifying Fan Connectors Poles

Courtesy of BMW OF NORTH AMERICA, INC.

Special tool 61 9 041 (hand crimping tool) in conjunction with 61 9 042 (matrix) are used for pushing contact sleeves onto fan connectors.

Refer to repair instructions:

Special tools for wiring harness repairs .

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

Courtesy of BMW OF NORTH AMERICA, INC.

Unlock special tool 61 9 041:

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

Or:

Compress handles as far as they will go, tool unlocks automatically.

Fig 9: Pushing Unlocking Lever

Courtesy of BMW OF NORTH AMERICA, INC.

Insert prepared fan connector (3) in special tool 61 9 041 / 61 9 042 .

Fig 10: Inserting Prepared Fan Connector In Special Tool

Courtesy of BMW OF NORTH AMERICA, INC.

Attach wire with contact sleeve to fan connector.

Fig 11: Attaching Wire With Contact Sleeve To Fan Connector

Courtesy of BMW OF NORTH AMERICA, INC.

Press crimping tool together and slide contact sleeve firmly home.

Fig 12: Pressing Crimping Tool

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Once contact sleeves have been pushed on, they should not be detached again from the fan connector or reused.

Push on further contact sleeves for potential branching.

Fig 13: Pushing On Further Contact Sleeves

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 shrink-fit hose and heat up with hot air blower (2) (approx. 250°C).

NOTE: Ensure that fan connector has sufficient contact surface on mounting point.
Do not heat shrink-fit hose on edges of fan connector too strongly, risk of cracking.

Fig 14: Fitting Shrink-Fit Hose

Courtesy of BMW OF NORTH AMERICA, INC.

Allow shrink-fit hose to cool down until hand-warm. Then press sealing material again into contacts and onto edges of fan connector.

If necessary, carefully heat shrink-fit hose again.

Installation in dry area (interior, luggage compartment):

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

Fig 15: Sliding Assembled Fan Connector Into Insulation Housing

Courtesy of BMW OF NORTH AMERICA, INC.