61 13... Crimping stop parts

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 And Nest

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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: Releasing Special Tool (12 1 081)

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

   Fig 3: Locating Safeguard

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

   Fig 4: Identifying Contact

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   NOTE: Follow procedure for CUTTING AND STRIPPING INSULATION  from cables.

   Insert stripped end of wire (1) 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 Crimp And Wire Crimp

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   Correct crimping: 

   Visible conductor end (10).

   Visible insulation end (11).

   Fig 7: Identifying Visible Insulation End And Visible Conductor End (Correct Crimping)

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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 Incorrect Crimping (Conductor End Inserted Too Far)

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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 Incorrect Crimping (Conductor End Not Visible)

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Special tools required: 

• 61 4 320
• 61 4 340
• 61 0 210
• 61 0 220
• 61 0 230

Necessary preliminary tasks: 

• See OPENING CONTACTS AND LOCKS OF DIFFERENT CONNECTOR SYSTEMS .
• See CUTTING CABLES TO LENGTH AND STRIP INSULATION 

1. Crimping stops up to 2.5 mm  ² 

   Crimping MICRO QUADLOCK SYSTEM CONTACTS (MQS) .

   • Special tool 61 4 320

   Crimping MICRO POWER QUADLOCK CONTACTS (MPQ) .

   • Special tool 61 4 320

   Crimping miscellaneous stop parts up to 2.5 mm²

   • Special tool 61 4 340 (up to 03/2010 SWZ 61 4 328)
2. Crimping stops from to 2.5 mm  ² 

   Crimping load current contacts (LSK 8).

   • Special tool 61 0 210

   Crimping SLK 2.8.

   • Special tool 61 0 220

   Crimping double spring contact (DFK 40)

   Crimping MAK 8

   • Special tool 61 0 230

   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 1: Identifying Insulation Crimp And Wire Crimp

   Courtesy of BMW OF NORTH AMERICA, INC.

   Correct crimping: 

   Visible conductor end (10).

   Visible insulation end (11).

   Fig 2: Identifying Visible Insulation End And Visible Conductor End (Correct Crimping)

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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 3: Identifying Incorrect Crimping (Conductor End Inserted Too Far)

   Courtesy of BMW OF NORTH AMERICA, INC.

   Incorrect crimping: 

   Conductor end (10) not visible.

   Insulation end (11) not visible.

   If necessary, repeat crimping with a new contact.

   Fig 4: Identifying Incorrect Crimping (Conductor End Not Visible)

   Courtesy of BMW OF NORTH AMERICA, INC.