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

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 Department.

Fig 1: Identifying Repair Kit Box

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Special tools:

Special tool 61 9 040

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 mm ² ) for comb connectors.

Fig 3: Identifying Contact Sleeves For Comb Connectors

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Cut through wire loop in wiring harness at established point.

Strip insulation from both wire ends.

CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES

Fig 4: Checking Maximum Length Of Repair Cable

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Crimp contact sleeves on both wire ends.

CRIMPING ON STOP PARTS

NOTE: If using repair kit for contact sleeves, refer to:
BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION .

Fig 5: Identifying Repair Kit For Contact Sleeves

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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 Number Of 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.

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 release lever (2) in direction of arrow.

Or:

Compress handles until limit position, hand pliers unlock automatically.

Fig 9: Identifying Squeeze Grips And 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 Contact Sleeve To Limit Position

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IMPORTANT: Once contact sleeves have been pushed on, they should not be detached again from the comb connector or reused.

Push on further contact sleeves for potential branching.

Fig 13: Identifying 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 heat-shrink tubing and heat up with hot air blower (2) (approx. 250 °C).

NOTE: Ensure that comb connector has sufficient contact surface on attachment point.

Do not heat-shrink tubing on edges of comb connector too strongly, risk of cracking.

Fig 14: Identifying Sealing Compound On Both Sides Into Contacts

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Allow heat-shrink tubing to cool down until hand-warm. Then press sealing material again into contacts and onto edges of comb connector.

If necessary, carefully heat-shrink tubing again.

Installation in dry area (interior, luggage compartment):

Slide assembled comb connector into insulation housing until it locks into place.

Fig 15: Sliding Assembled Comb Connector Into Insulation Housing

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