61 13... Crimping stop parts

Special tools required: 

• 12 1 080
• 12 1 081
• 12 1 083

The following spare parts can be obtained via BMW/MINI parts catalogue:

1. Butt connectors and contact sleeves for comb connectors up to 2.5 mm
2. Butt connectors and contact sleeves for comb connectors larger than 2.5 mm2
3. Contact sleeves for 4 mm² comb connectors and ignition cable contacts

   Use the following special tools (from kit 12 1 080 ) to attach ignition cable contacts and crimp 4 mm² contact sleeves for comb connectors:

   • 12 1 081 (hand pliers)
   • 12 1 083 (nest)

   Also, refer to SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

   Fig 1: Identifying Hand Pliers And Nest

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   Release special tool 12 1 081 :

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

   Or:

   Compress handles until limit position, hand pliers unlock automatically.

   Fig 2: Releasing Special Tool (12 1 081)

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   Place 4 mm² contact sleeve in nest with anti-twist safeguard (1) as far as possible.

   Fig 3: Inserting Contact Sleeve In Nest

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

   Fig 4: Griping Contact

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   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 to limit position.

   Crimping tool unlocks automatically.

   Take contact out of crimping tool.

   Fig 5: Inserting Stripped End Of Wire In Contact

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

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

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

   Courtesy of BMW OF NORTH AMERICA, INC.

Correct crimping: 

Visible conductor end (10).

Visible insulation end (11).

Incorrect crimping: 

Conductor end (10) inserted too far.

Insulation end (11) in wire crimp.

If necessary, repeat crimping with a new contact.

Incorrect crimping: 

Conductor end (10) not visible.

Insulation end (11) not visible.

If necessary, repeat crimping with a new contact.

Special tools required: 

• 0 494 159
• 0 496 849
• 0 496 833
• 2 407 379
• 61 4 320
• 61 4 340
• 61 0 210
• 61 0 220
• 61 0 230

Necessary preliminary work: 

• Refer to applicable service information for PLUG CONNECTIONS, TERMINALS, POWER DISTRIBUTION BOX .
• Refer to information for CUTTING CABLES TO LENGTH AND STRIP INSULATION 

1. Crimping of stops up to 2.5 mm ²  : 
   • Required special tool: 61 4 320 .
   • Refer to CRIMPING MICRO QUADLOCK SYSTEM CONTACTS (MQS)  and CRIMPING MICRO POWER QUADLOCK CONTACTS (MPQ) .
2. Crimping miscellaneous stop parts up to 2.5 mm ²  : 
   • Required special tool: 61 4 340 .
3. Crimping of stops above 2.5 mm ²  : 
   • Required special tool for crimping load current contacts (LSK 8): 61 0 210 .
   • Required special tool for crimping SLK 2.8 contacts: 61 0 220 .
   • Required special tool for crimping double spring contacts (DFK 40) and MAK 8 contacts: 61 0 230 .

Checking crimping: 

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

Correct crimping: 

Visible conductor end (10).

Visible insulation end (11).

Incorrect crimping: 

1. Conductor end (10) inserted too far, or insulation end (11) in wire crimp.

   (if necessary, re-crimp with a new contact)

   Fig 3: Incorrect Crimping (Conductor End Inserted Too Far)

   Courtesy of BMW OF NORTH AMERICA, INC.
2. Conductor end (10) not visible, or insulation end (11) not visible.

   (if necessary, re-crimp with a new contact)

   Fig 4: Identifying Incorrect Crimping (Conductor End Not Visible)

   Courtesy of BMW OF NORTH AMERICA, INC.