61 13... Installing comb connector for retrofitting/repairs: Notes

Special tools required: 

• 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 Department.

Fig 1: Identifying Vehicle Electrical System Special Repair Tools

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

Fig 2: Identifying Contact Sleeve (Up To 4 mm2)

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Alternatively:

Choose contact sleeves (up to 2.5 mm² ) or comb connectors.

Fig 3: Identifying Contact Sleeve (Up To 2.5 mm2)

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Cut through wire loop in wiring harness at established point.

Strip insulation from both wire ends.

Fig 4: Identifying Wire Stripper

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Crimp contact sleeves on both wire ends.

Fig 5: Identifying Contact Sleeves With And Without Crimped Ends

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Crimp connecting cable for retrofitting likewise with contact sleeve.

Fig 6: Crimping Connecting Cable For Retrofitting)

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Cut required number of poles to length for comb connectors.

Fig 7: Identifying Comb Connectors Poles)

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

Fig 8: Identifying Hand Pliers

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Unlock special tool 61 9 041 :

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

Or:

Compress handles until limit position, hand pliers unlock automatically.

Fig 9: Pushing Release Lever

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Insert prepared comb connectors (3) in special tool 61 9 041 / 61 9 042 .

Fig 10: Inserting Prepared Comb Connectors In Special Tool (61 9 041 / 61 9 042)

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Attach wire with contact sleeve to comb connector.

Fig 11: Attaching Wire With Contact Sleeve To Comb Connector

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Press hand pliers together and slide on contact sleeve until limit position.

Fig 12: Sliding Hand Pliers On Contact Sleeve

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