61 13 Installing Fan Connector For Retrofitting/Repairs

Special tools required: 

• 61 9 040 
• 61 9 041 
• 61 9 042 

Special tools: 

• special tool 61 9 040  . See 61 9 040 SET OF TOOLS FOR REPAIR KIT IV
  Fig 1: Identifying Repair Kit

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Choose contact sleeve (up to 4 mm ² ) in accordance with wire cross-section.

Fig 2: Identifying Contact Sleeve

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Alternatively:

Choose contact sleeves (up to 2.5 mm 2) 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  . 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.

Refer to repair instructions: 

Crimping on stop parts  . See 61 13 CRIMPING STOP PARTS 

Butt connector for repairing a plug connection.  . See 61 13 BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION 

Fig 5: Identifying Contact Sleeves On Both Wire Ends

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Crimp connecting cable for retrofitting likewise with contact sleeve.

Fig 6: Crimping Connecting Cable For Retrofitting Likewise

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Cut required number of poles to length for fan connectors.

Fig 7: Identifying Number Of Poles

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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  . See 61 13 SPECIAL TOOLS FOR WIRING HARNESS REPAIRS 

Fig 8: Identifying Special Tool

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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 Grips & Unlocking Lever

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

Fig 10: Inserting Prepared Fan Connector In Special Tool

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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: Pressing Crimping Tool

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