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. Order individual parts for wiring harness repair through BMW Parts Service.

Fig 1: Identifying Special Tools For Vehicle Electrical System Repairing

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

Fig 2: Identifying Contact Sleeves

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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.

See repair instructions:

CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES

Fig 4: Identifying Plier

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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 instruction:

BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION .

Fig 5: Identifying Crimp Contact Sleeves On Wire End

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Crimp connecting cable for retrofitting likewise with contact sleeve.

Fig 6: Identifying Crimp Connecting Cable For Retrofitting

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Cut required number of poles to length for fan connectors.

Fig 7: Identifying 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.

See repair instructions:

SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

Fig 8: Identifying Special Tool 61 9 041 (Hand Crimping Tool)

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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: Pushing Unlocking Lever

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

Fig 10: Inserting Fan Connectors In Special Tool (61 9 041 / 61 9 042)

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Attach wire with contact sleeve to fan connector.

Fig 11: Attaching Wire With Contact Sleeve To Fan Connector

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Press crimping tool together and slide contact sleeve firmly home.

Fig 12: Pressing Crimping Tool

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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 fan connector for retrofitting/repairs: Notes

Use the Manual With the Right Hardware

When to See a Mechanic

Rather have a pro handle this?