Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSBMW2009X5 35DREPAIR AND DIAGNOSISRESTRAINTSAIR BAG, SRSGENERAL ELECTRICAL SYSTEM - REPAIR13 PLUG CONNECTION, TERMINAL, FUSE BOX61 13 SPECIAL TOOLS FOR WIRING HARNESS REPAIRS

2009 BMW X5 35d

61 13 Special Tools For Wiring Harness Repairs

2009 BMW X5 35dSECTION 61 13 Special Tools For Wiring Harness Repairs

Special tools required:

12 1 080
61 0 200
61 0 210
61 0 220
61 0 230
61 0 300
61 0 400
61 1 190
61 4 320
61 9 041
61 9 044

Repair range, vehicle electrical system:

Release and press-out tool:

Special tool 61 0 300
Special tool 61 0 400 (MINI N12/N14)

Handling:

Opening plug housings and removing contacts of different plug systems. See 61 13 OPENING PLUG HOUSINGS AND REMOVING CONTACTS OF DIFFERENT PLUG SYSTEMS .

Fig 1: Identifying Special Tool Kit

Courtesy of BMW OF NORTH AMERICA, INC.

Cutting to length and stripping insulation from cables:

Handling:

Cutting to length and stripping insulation from cables . See 61 13 CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES .

Fig 2: Identifying Cutting Tool
Courtesy of BMW OF NORTH AMERICA, INC.

Crimping stop parts (small contacts):

Special tool 61 4 320
1. Tool without crimping head
2. Crimping head (stripping insulation and cutting fiber-optic cables to length )
3. Crimping head (crimping fiber-optic cable contacts )
4. Crimping head (crimping MQS contacts )
5. Crimping head (crimping MPQ contacts )
6. Replacement blade (face-cutting fiber-optic cables)
7. Replacement blade with tool (insulation stripping unit)
8. Universal crimping head (SI 2 04 06 293 )
  
  Fig 3: Identifying Crimping Stop Parts (Small Contacts)
  Courtesy of BMW OF NORTH AMERICA, INC.

Crimping stop parts (large contacts):

Special tool 61 0 200 (crimping set)
Special tool 61 0 210 (matrix set LSK 8)
Special tool 61 0 220 (matrix set SLK 2.8)
Special tool 61 0 230 (matrix set MAK 8 / DFK4)

Fig 4: Identifying Crimping Stop Parts (Large Contacts)

Courtesy of BMW OF NORTH AMERICA, INC.

Crimping antenna elbow plugs:

Special tool 61 9 041 (hand crimping tool)
Special tool 61 9 044 (matrix)

Handling:

Antenna elbow plug on radio receiver

Fig 5: Identifying Special Tool 61 9 041 And 61 9 044
Courtesy of BMW OF NORTH AMERICA, INC.

Repair kit for ignition cables and for crimping fan connector receptacles 4 mm ² :

Special tool 12 1 080

Handling:

Crimping stop parts (contacts) . See 61 13 CRIMPING STOP PARTS .

Fig 6: Identifying Repair Kit For Ignition Cables
Courtesy of BMW OF NORTH AMERICA, INC.

Repairing ribbon cables:

Special tool 61 1 190

Handling:

Repairing ribbon cables

Fig 7: Identifying Special Tool 61 1 190
Courtesy of BMW OF NORTH AMERICA, INC.

RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.
• Brakes feel soft, pull hard to one side, or make grinding noises.
• The engine overheats, stalls repeatedly, or misfires under load.
• You are missing required tools, torque specs, or safe lifting equipment.
• You are not confident in the next step or safety outcome.