61 13... Crimping stop parts

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Special tools required:

Crimping contact sleeves for 4 mm2 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: Identifying 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
Courtesy of BMW OF NORTH AMERICA, INC.

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: Gripping Contact
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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: Inserting Stripped End Of Wire
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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: Checking Insulation Crimping And Wire Crimp
Courtesy of BMW OF NORTH AMERICA, INC.

Correct crimping:

Visible conductor end (10).

Visible insulation end (11).

Fig 7: Identifying Correct Crimping
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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:

Crimping of NanoMQS stops (only G11; G12)
Crimping of NanoMQS contacts (MQS).
- Special tool handle 0 494 159 or 0 496 849
- Special tool (die-plate) 0 496 833
- Stripping tool2 407 379
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)
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.

NOTE: Illustration shows butt connectors and contact sleeves for comb connectors knocked on one side. The crimping procedure is identical here.

Fig 1: Checking Insulation Crimping And Wire Crimp

Courtesy of BMW OF NORTH AMERICA, INC.

Correct crimping:

Visible conductor end (10).

Visible insulation end (11).

Fig 2: Identifying Correct Crimping

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.