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 MANUALSBMW2010528XI STANDARDREPAIR AND DIAGNOSISRESTRAINTSAIR BAG, SRSGENERAL ELECTRICAL SYSTEM - REPAIRPLUG CONNECTION, TERMINALS, FUSE BOX61 13... INSTALLING FAN CONNECTOR FOR RETROFITTING/REPAIRS

2010 BMW 528xi Standard

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

2010 BMW 528xi StandardSECTION 61 13... Installing fan 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.

Special tools:

special tool 61 9 040

Fig 1: Identifying Repair Kit
Courtesy of BMW OF NORTH AMERICA, INC.

Choose contact sleeve (up to 4 mm² ) in accordance with wire cross-section.

Fig 2: Identifying Contact Sleeve

Courtesy of BMW OF NORTH AMERICA, INC.

Alternatively:

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

Fig 3: Identifying Contact Sleeves For Fan Connectors

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Cut through wire loop in wiring harness at established point.

Strip insulation from both wire ends.

Refer to repair instructions:

CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES

Fig 4: Identifying Special Tool

Courtesy of BMW OF NORTH AMERICA, INC.

Crimp contact sleeves on both wire ends.

Refer to 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: Identifying Contact Sleeves On Both Wire Ends

Courtesy of BMW OF NORTH AMERICA, INC.

Crimp connecting cable for retrofitting likewise with contact sleeve.

Fig 6: Crimping Connecting Cable For Retrofitting Likewise

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Cut required number of poles to length for fan connectors.

Fig 7: Identifying Number Of Poles

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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.

Refer to repair instructions:

SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

Fig 8: Identifying Special Tool

Courtesy of BMW OF NORTH AMERICA, INC.

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: Identifying Grips And Unlocking Lever

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

Fig 10: Inserting Prepared Fan Connector In Special Tool

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Attach wire with contact sleeve to fan connector.

Fig 11: Attaching Wire With Contact Sleeve To Fan Connector

Courtesy of BMW OF NORTH AMERICA, INC.

Press crimping tool together and slide contact sleeve firmly home.

Fig 12: Pressing Crimping Tool

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.