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

Special tools required: 

• 61 9 041
• 61 9 042

The case can no longer be ordered. Order individual parts for wiring harness repair.

Fig 1: Vehicle Electrical System Special Tools Kit

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

Fig 2: Contact Sleeves

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Alternatively:

Choose contact sleeves (up to 2.5 mm ² ) or comb connectors.

Fig 3: Contact Sleeves And Comb Connectors

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Cut through wire loop in wiring harness at established point.

Strip insulation from both wire ends.

See repair instructions 

CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES 

Fig 4: Crimp Tool

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Crimp contact sleeves on both wire ends.

See repair instructions 

CRIMPING ON STOP PARTS 

BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION .

Fig 5: Crimp Contact Sleeves On Wire End

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Crimp connecting cable for retrofitting likewise with contact sleeve.

Fig 6: Crimp Connecting Cable For Retrofitting

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Cut required number of poles to length for comb connectors.

Fig 7: 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.

See repair instructions 

SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

Fig 8: Special Tool (61 9 041)

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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 Fan Connectors On 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: Pressing Hand Pliers

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