61 13... Crimping stop parts

Special tools required: 

• 12 1 080
• 12 1 081
• 12 1 083

Spare parts for in-car electronics (housing and contacts): 

1. Crimping butt connectors and contact sleeves for comb connectors up to 2.5 mm 
2. Crimping butt connectors and contact sleeves for comb connectors larger than 2.5 mm2 
3. Crimping contact sleeves for 4 mm ²  comb connectors and ignition cable contacts 

   Use special tool kit 12 1 080 to attach ignition cable contacts and crimp 4 mm² contact sleeves for comb connectors.

   • 12 1 081 (hand pliers)
   • 12 1 083 (nest)

   See repair instructions 

   Special tools for wiring harness repairs.

   Fig 1: Hand Pliers (12 1 081) And Nest (12 1 083)

   Courtesy of BMW OF NORTH AMERICA, INC.

   Release special tool 12 1 081 :

   Squeeze grips (1) lightly and push release lever (2) in direction of arrow.

   Or:

   Compress handles until limit position, hand pliers unlock automatically.

   Fig 2: Pushing Release Lever

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   Place 4 mm² contact sleeve in nest with anti-twist safeguard (1) as far as possible.

   Fig 3: Inserting Contact Sleeve

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   Preload contact by squeezing matrix in crimping tool. Grip contact (1) firmly only, do not crimp.

   Fig 4: Grip Contact

   Courtesy of BMW OF NORTH AMERICA, INC.
   NOTE: Follow procedure for cutting and stripping insulation from cables.

   Insert stripped end of wire (7) in the contact. Ensure insulation and stripped wire end are correctly laid in contact.

   Compress crimping tool to limit position.

   Crimping tool unlocks automatically.

   Take contact out of crimping tool.

   Fig 5: Compressing Crimping Tool

   Courtesy of BMW OF NORTH AMERICA, INC.
4. Checking crimping 

   Check insulation crimping (8) and wire crimp (9) against following illustrations to ensure crimps are correctly located.

   NOTE: Illustration shows butt connectors and contact sleeves for comb connectors knocked on one side. The crimping procedure is identical here.
   Fig 6: Crimping Insulation And Wire Crimp

   Courtesy of BMW OF NORTH AMERICA, INC.

   Correct crimping: 

   Visible conductor end (10).

   Visible insulation end (11).

   Fig 7: Conductor And Insulator Ends

   Courtesy of BMW OF NORTH AMERICA, INC.

   Incorrect crimping: 

   Conductor end (10) inserted too far.

   Insulation end (11) in wire crimp.

   If necessary, repeat crimping with a new contact.

   Fig 8: Incorrect Crimping (Conductor End Inserted Too Far)

   Courtesy of BMW OF NORTH AMERICA, INC.

   Incorrect crimping: 

   Conductor end (10) not visible.

   Insulation end (11) not visible.

   If necessary, repeat crimping with a new contact.

   Fig 9: Incorrect Crimping (Conductor End Not Visible)

   Courtesy of BMW OF NORTH AMERICA, INC.

Special tools required: 

• 0 494 159
• 0 496 849
• 0 496 833
• 2 407 379
• 61 4 320
• 61 4 340
• 61 0 210
• 61 0 220
• 61 0 230

Necessary preliminary work: 

• OPENING PLUG HOUSINGS AND REMOVING CONTACTS OF DIFFERENT PLUG SYSTEMS .
• CUTTING CABLES TO LENGTH AND STRIP INSULATION .

Special tools for wiring harness repair.

1. Crimping of stops up to 2.5 mm ² 

   Crimping MICRO QUADLOCK SYSTEM CONTACTS (MQS) .

   • Special tool 61 4 320

   Crimping MICRO POWER QUADLOCK CONTACTS (MPQ) .

   • Special tool 61 4 320

   Crimping miscellaneous stop parts up to 2.5 mm²

   • Special tool 61 4 340 (up to 03/2010 SWZ 61 4 328)
2. Crimping of stops above 2.5 mm2 

   Crimping load current contacts (LSK 8).

   • Special tool 61 0 210

   Crimping SLK 2.8.

   • Special tool 61 0 220

   Crimping double spring contact (DFK 40)

   Crimping MAK 8

   • Special tool 61 0 230

Checking crimping 

Check insulation crimping (8) and wire crimp (9) against following illustrations to ensure crimps are correctly located.

Fig 1: Crimping Insulation And Wire Crimp

Courtesy of BMW OF NORTH AMERICA, INC.

Correct crimping: 

Visible conductor end (10).

Visible insulation end (11).

Fig 2: Conductor And Insulator Ends

Courtesy of BMW OF NORTH AMERICA, INC.

Incorrect crimping: 

Conductor end (10) inserted too far.

Insulation end (11) in wire crimp.

If necessary, repeat crimping with a new contact.

Fig 3: Incorrect Crimping (Conductor End Inserted Too Far)

Courtesy of BMW OF NORTH AMERICA, INC.

Incorrect crimping: 

Conductor end (10) not visible.

Insulation end (11) not visible.

If necessary, repeat crimping with a new contact.

Fig 4: Incorrect Crimping (Conductor End Not Visible)

Courtesy of BMW OF NORTH AMERICA, INC.