61 13 Crimping stop parts

Special tools required: 

• 12 1 080 
• 12 1 081 
• 12 1 083 

1. Crimping butt connectors and contact sleeves for fan connectors up to 2.5 mm  ² 
2. Crimping butt connectors and contact sleeves for fan connectors from 2.5 mm  ² 
3. Crimping contact sleeves for fan connectors 4 mm  ²  and ignition cable contacts 

   Special tool kit 12 1 080  is used to fit ignition cable contacts and to crimp 4 mm² contact sleeves for fan connectors.

   • 12 1 081  (hand crimping tool)
   • 12 1 083  (matrix)

   Refer to repair instructions: 

   Special tools for wiring harness repairs  

   Fig 1: Special Tools (12 1 081) And (12 1 083)

   Courtesy of BMW OF NORTH AMERICA, INC.

   Unlock special tool 12 1 081  :

   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 2: Grips, Unlocking Lever And Unlocking Direction

   Courtesy of BMW OF NORTH AMERICA, INC.

   Insert contact sleeve 4 mm² in nest with lock (1) as far as it will go.

   Fig 3: Contact Sleeve And Lock

   Courtesy of BMW OF NORTH AMERICA, INC.

   Preload contact by squeezing matrix in crimping tool. Grip contact (1) firmly only, do not crimp.

   Fig 4: Grip Contact

   Courtesy of BMW OF NORTH AMERICA, INC.
   NOTE: Follow procedure for cutting and stripping insulation   from cables.

   Insert stripped end of wire (7) in the contact. Ensure insulation and stripped wire end are correctly laid in contact.

   Compress crimping tool as far as it will go.

   Crimping tool unlocks automatically.

   Take contact out of crimping tool.

   Fig 5: Identifying Stripped End Of Wire In Contact

   Courtesy of BMW OF NORTH AMERICA, INC.
4. Checking crimping 

   Check insulation crimp (8) and wire crimp (9) against following illustrations to ensure crimps are correctly located.

   NOTE: Illustration shows butt connectors and contact sleeves for fan connectors knocked on one side. The crimping procedure is identical here.
   Fig 6: Identifying Insulation Crimp And Wire Crimp

   Courtesy of BMW OF NORTH AMERICA, INC.

   Correct crimping: 

   Visible conductor end (10).

   Visible insulation end (11).

   Fig 7: Identifying Correct Crimping And Visible Conductor End

   Courtesy of BMW OF NORTH AMERICA, INC.

   Incorrect crimping: 

   Conductor end (10) inserted too far.

   Insulation end (11) in wire crimp.

   If necessary, repeat crimping with a new contact.

   Fig 8: Identifying Incorrect Crimping And Conductor End Inserted Too Far

   Courtesy of BMW OF NORTH AMERICA, INC.

   Incorrect crimping: 

   Conductor end (10) not visible.

   Insulation end (11) not visible.

   If necessary, repeat crimping with a new contact.

   Fig 9: Identifying Incorrect Crimping And Conductor End Not Visible

   Courtesy of BMW OF NORTH AMERICA, INC.