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.

Special tools:

Fig 1: Identifying Special Tools Kit

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Special tool 61 9 040

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

Fig 2: Identifying Comb Connector Contact Sleeve

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Alternatively:

Choose contact sleeves (up to 2.5 mm 2) for comb connectors.

Fig 3: Identifying Comb Connector Contact Sleeve

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Cut through wire loop in wiring harness at established point.

Strip insulation from both wire ends.

See repair instructions

CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES

Fig 4: Identifying Stripping Tool

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Crimp contact sleeves on both wire ends.

See repair instructions

CRIMPING ON STOP PARTS

NOTE: If using repair kit for contact sleeves, refer to repair instructions:

BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION .

Fig 5: Identifying Connector Crimping Parts

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Crimp connecting cable for retrofitting likewise with contact sleeve.

Fig 6: Identifying Crimp Cable

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Cut required number of poles to length for comb connectors.

Fig 7: Identifying Comb Connectors 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.

See repair instructions

SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

Fig 8: Identifying Special Tool (61 9 041)

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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: Pressing Hand Pliers

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Insert prepared comb connectors (3) in special tool 61 9 041 /61 9 042 .

Fig 10: Inserting Comb Connectors In Special Tool (61 9 041)

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Attach wire with contact sleeve to comb connector.

Fig 11: Attaching Wire With Contact Sleeve To Comb Connector

Courtesy of BMW OF NORTH AMERICA, INC.

Press hand pliers together and slide on contact sleeve until limit position.

Fig 12: Pressing Hand Pliers

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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.

Safety Warning

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

Use the Manual With the Right Hardware

When to See a Mechanic

Rather have a pro handle this?