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.

Special tools:

Special tool 61 9 040

Fig 1: Identifying Wiring Harness Repair Kit
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Choose contact sleeve (up to 4 mm² ) in accordance with wire cross-section.

Fig 2: Identifying Contact Sleeve

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Alternatively:

Choose contact sleeves (up to 2.5 mm² ) for fan connectors.

Fig 3: Identifying Fan Connectors Contact Sleeves

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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: Identifying Crimp Tool

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Crimp contact sleeves on both wire ends.

See 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: Crimping 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 With Contact Sleeve

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Cut required number of poles to length for fan connectors.

Fig 7: Identifying Fan Connectors Poles Length

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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.

See repair instructions

SPECIAL TOOLS FOR WIRING HARNESS REPAIRS

Fig 8: Identifying Special Tool 61 9 041 (Hand Crimping 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: Pushing Unlocking Lever In Direction Of Arrow

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

Fig 10: Inserting Prepared Fan Connectors In Special Tool 61 9 041/61 9 042

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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 Together And Slide Contact Sleeve Firmly Home

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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: Pushing On Further Contact Sleeves For Potential Branching

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