61 13 Installing Fan Connector For Retrofitting/Repairs

WARNING: This page is about a different car, the 2007 BMW 550i and 2006 BMW 550i. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

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 Repair Kit

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

Fig 2: Identifying Contact Sleeve 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.

Refer to repair instructions:

CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES

Fig 4: Identifying Wire With Faulty Contact At Point

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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 instruction

BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION.

Fig 5: Identifying Crimp Contact Sleeves On Both Wire Ends

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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 Poles To Length For 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.

Refer to repair instructions:

SPECIAL TOOLS FOR WIRING HARNESS REPAIRS

Fig 8: Identifying Special Tools For Wiring Harness Repairs

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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 Locking Lever And Squeeze Grips

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

Fig 10: Identifying Prepared Fan Connector

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Attach wire with contact sleeve to fan connector.

Fig 11: Attaching Wire With Contact Sleeve To Fan Connector

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Press crimping tool together and slide contact sleeve firmly home.

Fig 12: Identifying Wire With Contact Sleeve To Fan Connector

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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 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 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 Wet Area

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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 Into Insulation Housing

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