Special Tools Required

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2013 BMW 128i, 2012 BMW 128i, 2011 BMW 128i, 2010 BMW 135i, and 2010 BMW 128i. However, it is still accessible from the selected car via links, so may be relevant.

61 9 040
61 9 041
61 9 042

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.

Special tools:

special tool 61 9 040

Fig 1: Identifying Special Tools
Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 2: Cross-Section View Of Wire

Courtesy of BMW OF NORTH AMERICA, INC.

Alternatively:

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

Fig 3: Cutting Wire Loop

Courtesy of BMW OF NORTH AMERICA, INC.

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 Tools

Courtesy of BMW OF NORTH AMERICA, INC.

Crimp contact sleeves on both wire ends.

NOTE: If using repair kit for contact sleeves, refer to repair instruction:
BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION .

Fig 5: Crimping 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

Courtesy of BMW OF NORTH AMERICA, INC.

Cut required number of poles to length for fan connectors.

Fig 7: Identifying Fan Connectors

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

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: Pushing Unlocking Lever

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 Contact Sleeves

Courtesy of BMW OF NORTH AMERICA, INC.