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

Special tools required:

61 9 040
61 9 041
61 9 042

NOTE:

See GENERAL ELECTRICAL SYSTEM - SPECIAL TOOLS .

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.

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 In Wire Cross-Section

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

Courtesy of BMW OF NORTH AMERICA, INC.

Cut through wire loop in wiring harness at established point.

Strip insulation from both wire ends.

Fig 4: Identifying Special Tool

Courtesy of BMW OF NORTH AMERICA, INC.

Crimp contact sleeves on both wire ends.

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

Courtesy of BMW OF NORTH AMERICA, INC.

Cut required number of poles to length for fan connectors.

Fig 7: Identifying Fan Connectors Poles

Courtesy of BMW OF NORTH AMERICA, INC.

Special tool 61 9 041 (hand crimping tool) in conjunction with 61 9 042 (matrix) are used for pushing contact sleeves onto fan connectors.

Fig 8: Identifying Special Tools For Wiring Harness Repairs

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 Unlocking Lever And Squeeze Grips

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 10: Inserting Prepared Fan Connector

Courtesy of BMW OF NORTH AMERICA, INC.

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.

IMPORTANT: Once contact sleeves have been pushed on, they should not be detached again from the fan connector or reused.

Push on further contact sleeves for potential branching.

Fig 13: Identifying Further Contact Sleeves For Potential Branching

Courtesy of BMW OF NORTH AMERICA, INC.

Installation in wet area (engine compartment, wheel arch):

Apply sealing compound on both sides and press into contacts (1).

Fit shrink-fit hose and heat up with hot air blower (2) (approx. 250°C).

Fig 14: Fitting Shrink-Fit Hose And Hot Air Blower

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Ensure that fan connector has sufficient contact surface on mounting point.

Do not heat shrink-fit hose on edges of fan connector too strongly, risk of cracking.

Allow shrink-fit hose to cool down until hand-warm. Then press sealing material again into contacts and onto edges of fan connector.

If necessary, carefully heat shrink-fit hose again.

Installation in dry area (interior, luggage compartment):

Slide assembled fan connector into insulation housing until it locks into place.

Fig 15: Sliding Assembled Fan Connector Into Insulation Housing

Courtesy of BMW OF NORTH AMERICA, INC.