61 13 Installing Fan Connector For Retrofitting/Repairs

WARNING: This page is about a different car, the 2008 BMW Alpina and 2007 BMW Alpina. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

61 9 040
61 9 041
61 9 042

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

Fig 2: Identifying Contact Sleeve In Accordance With Wire Cross-Section

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Alternatively:

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

Fig 3: Identifying Contact Sleeves For Fan Connectors

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Cut through wire loop in wiring harness at established point.

Strip insulation from both wire ends.

Cutting to length and stripping insulation from cables . See 61 13 CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES .

Fig 4: Identifying Special Tool

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Crimp contact sleeves on both wire ends.

Crimping on stop parts

NOTE: If using repair kit for contact sleeves, refer to repair instruction.
Butt connector for repairing a plug connection. See 61 13 BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION .

Fig 5: Identifying Crimping On Stop Parts

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Crimp connecting cable for retrofitting likewise with contact sleeve.

Fig 6: Identifying Crimp Connecting Cable For Retrofitting Likewise With Contact Sleeve

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Cut required number of poles to length for fan connectors.

Fig 7: Identifying Fan Connectors

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

Special tools for wiring harness repairs . See 61 13 SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

Fig 8: Identifying Special Tools

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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: Identifying Squeeze Grips And Unlocking Lever

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

Fig 10: Identifying Fan Connector

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Attach wire with contact sleeve to fan connector.

Fig 11: Identifying Wire And Contact Sleeve To Fan Connector

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Press crimping tool together and slide contact sleeve firmly home.

Fig 12: Identifying Crimping Tool And Slide Contact Sleeve

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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: Identifying Contact Sleeves And Fan Connector

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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.

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.

Fig 14: Identifying Sealing Compound On Both Sides

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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 In Insulation Housing

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