Special tools required:
Spare parts for in-car electronics (housing and contacts):
Special tool kit 12 1 080 is used to fit ignition cable contacts and to crimp 4 mm2 contact sleeves for fan connectors.
Fig. 43: Identifying Special Tool 12 1 081 And 12 1 083
Unlock special tool 12 1 081:
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. 44: Pushing Unlocking Lever
Insert contact sleeve 4 mm2 in nest with lock (1) as far as it will go.
Fig. 45: Identifying Lock
Preload contact by squeezing matrix in crimping tool. Grip contact (1) firmly only, do not crimp.
Fig. 46: [Identifying Grip Contact]
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 as far as it will go.
Crimping tool unlocks automatically.
Take contact out of crimping tool.
Fig. 47: Identifying Crimping Tool
Check insulation crimp (8) and wire crimp (9) against following illustrations to ensure crimps are correctly located.
NOTE: Illustration shows butt connectors and contact sleeves for fan connectors knocked on one side. The crimping procedure is identical here.
Fig. 48: Identifying Insulation Crimp And Wire Crimp
Correct crimping:
Visible conductor end (10).
Visible insulation end (11).
Fig. 49: Identifying Conductor End And Insulation End
Incorrect crimping:
Conductor end (10) inserted too far.
Insulation end (11) in wire crimp.
If necessary, repeat crimping with a new contact.
Fig. 50: Identifying Incorrect Crimping
Incorrect crimping:
Conductor end (10) not visible.
Insulation end (11) not visible.
If necessary, repeat crimping with a new contact.
Fig. 51: Identifying Incorrect Crimping
CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES
Stripped length:
STRIPPED LENGTH SPECIFICATION