Special tools required
- 61 1 150
- 61 1 190
- 61 4 320
- 61 8 084
- 61 9 020
- 61 9 029
- 61 9 041
- 61 9 042
- 61 9 043
- 61 9 044
Repair ranges I, II, III for vehicle electrical system
- Order No.: 81 24 9 408 080
- Order No.: 81 24 9 408 300
- Order No.: 81 24 9 408 400
Sourcing reference: BMW Parts Service.
Scheme 27
Note. Operating instructions for the special tools contained in these repair ranges, refer to .
Repair range IV for vehicle electrical system, special tool 61 9 020
Contents
- Special tool 61 9 041 (hand pliers)
- Special tool 61 9 042 (matrix)
- Special tool 61 9 043 (wire stripper)
- Special tool 61 9 044 (matrix)
Scheme 28
Note. Operating instructions for the special tools contained in the this repair range, refer to .
Special tool 61 9 043 (wire stripper with wire cutter) for cutting and stripping wires.
Handling
Cutting to length and stripping insulating from cables
Scheme 29
Special tool 61 9 041 (hand pliers) with special tool 61 9 042 (matrix) for crimping connectors and contact tubes for fan connectors up to a wire cross-section of 2.5 mm2 and for pushing on contact tubes for fan connectors.
Handling
Crimping stop parts (contacts).
Fan connector for retrofitting/repairs.
Scheme 30
Special tool 61 9 041 (hand pliers) with special tool 61 9 044 (matrix) for crimping cable guide and strain relief device on antenna elbow plug.
Handling
Antenna elbow plug on radio receiver.
Scheme 31
Scheme 32
Special tool 61 1 150 (release and pressing-out tool) for
- releasing round plug housings
- releasing relay carriers
- pressing out contacts
- removing indicator lights
Handling
Opening plug housings and removing contacts of different plug systems Repair kit for ignition cables and for crimping fan connector receptacles 4 mm 2
Handling
Crimping stop parts (contacts).
Service Information 1 03 89 (037)
Scheme 33
Special tool 61 4 320 (crimping set with pliers) for
Scheme 34
- Cutting to length and stripping insulation from optical fibers
- Crimping optical fibers
- Crimping MPQ contacts
- Crimping MQS contacts
Special tool 61 1 190 pliers for insulation displacement connector for repairing ribbon cables.
Handling
Repairing ribbon cables.
Scheme 35
- 61 4 320
To crimp MPQ contacts, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 325 (2) from crimping set 61 4 320.
Note. Pliers (1) open automatically as far as they will go when handles are pressed together.
Scheme 36
Open pliers (1).
Note. Place contact (2) with utmost care in designated nest (observe cable cross-section) in crimping head (3). Make sure it is exactly positioned. Place MPQ contact (2) in crimping head (3).
Close pliers (1) one notch.
Scheme 37
Note. Follow procedure for cutting and stripping insulation from cables.
Insert stripped cable (2).
Close pliers (1) fully.
Open pliers (1) and remove cable (2).
Note. Check contact for correct crimping.
Scheme 38
- 61 4 320
To crimp MQS contacts, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 324 (2) from crimping set 61 4 320.
Note. Pliers (1) open automatically as far as they will go when handles are pressed together.
Scheme 39
Open pliers (1).
Fold up contact carrier (2).
Insert MQS contact (3) in contact carrier (2).
Fold back contact carrier (2).
Scheme 40
Note. Follow procedure for cutting and stripping insulation from cables.
Close pliers (1) one notch.
Insert stripped cable (2).
Close pliers (1) fully.
Scheme 41
Open pliers (1).
Open contact carrier (2) gently and carefully remove MQS contact.
Note. Check contact for correct crimping
Scheme 42
- 61 4 320
To cut off, strip insulation and cut optical fibres to length, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 322 (2) from crimping set 61 4 320.
Note. Pliers (1) open automatically as far as they will go when handles are pressed together.
Scheme 43
Cutting optical fibre
Open pliers (1).
Place optical fibre (2) in cutting device (3).
Close pliers (1) and remove optical fibre (2).
Scheme 44
Stripping insulation from optical fibre
Open pliers (1).
Open lever (2) in direction of arrow.
Scheme 45
Slide optical fibre (1) into stripping device (2) until flush at point (3).
Close pliers (4) fully.
Close clamping lever (5) in direction of arrow.
Open pliers (4) by one tooth notch.
Open clamping lever (5) against direction of arrow again and remove optical fibre (1).
Note. A stripping replacement blade set is available under number 61 4 327.
Scheme 46
Cutting optical fibre to length
| IMPORTANT | The cutting blade must be replaced prior to each cutting of the optical fibre. |
Pull pin (1) in direction of arrow.
Fold up blade retaining link (2) in direction of arrow.
Scheme 47
| WARNING | Risk of injury when changing the blade. |
Remove blade (1) and replace.
Installation
Make sure blade (1) is correctly seated on locating points (2).
Scheme 48
Open pliers (3).
Slide optical fibre (1) into cutting device (2) until insulation of optical fibre (1) butts against clamping device.
Close pliers (3) fully and keep closed.
Remove optical fibre (1).
Scheme 49
- 61 1 190
Place ribbon cables (1) in connector housing (2) and close cover (3).
Scheme 50
Place connector housing (1) in pliers (2) 61 1 190.
Close pliers (2).
Scheme 51
- 12 7 060
Note. Electrical components which are particularly sensitive to electrostatic discharge (electronic control units, sensors, etc.) are marked with the ESD warning symbol.
E-Electro
S-Static
D-Discharge
For further information on this subject, please refer to .
Scheme 52
Statically charged persons can discharge by touching electrical components.
Note. Humans can only detect a discharge starting from a level of approx. 3000 V.
The danger threshold for electrical components already starts from a level of approx. 100 V.
Scheme 53
| IMPORTANT | Do not touch pins or multi-pin connectors directly! Touch electrical components by their housings only. |
| IMPORTANT | To prevent electrical components from being damaged or destroyed by electrostatic discharge, it is absolutely essential to comply with the following instructions: When replacing electrical components, leave the replacement components in their original packaging until immediately before they are to be installed If necessary, always return a removed component in its original packaging (always pack the component away immediately) Read and comply with user information on using the associated ESD special tool 12 7 060 |
- 00 9 221
- 00 9 222
- 00 9 331
Note. Wiping quality is increased if the approach angle of the windshield wiper arms is precisely adjusted.
Place special tool 00 9 331 next to pivot point of windshield wiper blade on windshield.
Scheme 54
Note. To prevent the wiper arm from scratching the glass, cover the arm with adhesive tape. To adjust passenger windshield wiper arm, move it into vertical position.
If contact angle is too large (light gap at top between gauge and wiper blade), grip wiper arm with special tool 00 9 222 and turn in direction of arrow with special tool 00 9 221.
Scheme 55
Note. To prevent the wiper arm from scratching the glass, cover the arm with adhesive tape. To adjust passenger windshield wiper arm, move it into vertical position.
Scheme 56
If contact angle is too small (light gap at bottom between gauge and wiper blade), grip wiper arm with special tool 00 9 222 and turn in direction of arrow with special tool 00 9 221.
- 61 6 060
Lever out cap (1) at side and remove.
Scheme 57
Installation
Catches (1) of cap (2) must not be damaged.
Scheme 58
Unscrew nut (1).
Installation
- Observe tightening torque, 61 62 2AZ.
Scheme 59
Detach wiper arm (1) with special tool 61 6 060 and remove.
Scheme 60
Installation
- Wiper motor must be in end position.
- Adjust distance (1) between wiper arm and rear window edge.
(1) 32.5+/-2 mm
Scheme 61
- 00 9 317
Unclip plug connection (1) and disconnect.
Detach angle (2) or T-piece from jet nozzle.
Scheme 62
Unlock jet nozzle (1) with a suitable screwdriver (2).
Lever out jet nozzle (1) with special tool 00 9 317 and remove.
Installation
- Ensure hose is laid without kinks.
Adjust jet nozzle.
Scheme 63
- 00 9 317
Unclip plug connection (1) and disconnect.
Detach angle (2) or T-piece from jet nozzle.
Scheme 64
Unlock jet nozzle (1) with a suitable screwdriver (2).
Lever out jet nozzle (1) with special tool 00 9 317 and remove.
Installation
- Ensure hose is laid without kinks.
Adjust jet nozzle.
