BMW X5: Installing Fan Connector For Retrofitting/Repairs

Special tools required:

• 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. 52: Identifying BMW Special Tool Kit

Choose contact sleeve (up to 4 mm 2 ) in accordance with wire cross-section.

Fig. 53: Identifying Contact Sleeve

Alternatively:

Choose contact sleeves (up to 2.5 mm 2 ) for fan connectors.

Fig. 54: Identifying Contact Sleeves For Fan Connectors

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. 55: Identifying Cutting Tool

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. 56: Crimping Contact Sleeves On Both Wire Ends

Crimp connecting cable for retrofitting likewise with contact sleeve.

Fig. 57: Crimping Connecting Cable For Retrofitting Likewise With Contact Sleeve

Cut required number of poles to length for fan connectors.

Fig. 58: Identifying Poles

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

Refer to repair instructions:

SPECIAL TOOLS FOR WIRING HARNESS REPAIRS

Fig. 59: Identifying Special Tool 61 9 041 (Hand Crimping Tool)

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. 60: Pushing Unlocking Lever

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

Fig. 61: Inserting Prepared Fan Connector In Special Tool 61 9 041/61 9 042

Attach wire with contact sleeve to fan connector.

Fig. 62: Attaching Wire With Contact Sleeve To Fan Connector

Press crimping tool together and slide contact sleeve firmly home.

Fig. 63: Pressing Crimping Tool

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. 64: Identifying Contact Sleeves

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. 250ºC).

Fig. 65: Identifying Terminal Contacts

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. 66: Sliding Assembled Fan Connector Into Insulation Housing

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