Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Installing comb connector for retrofitting/repairs
Special tools required:
- 61 9 041
- 61 9 042
The case can no longer be ordered. Individual parts for wiring harness repair are available via BMW.
Choose contact sleeve (up to 4 mm2 ) in accordance with wire cross-section.
Alternatively:
Choose contact sleeves (up to 2.5 mm2 ) or comb connectors.
Cut through wire loop in wiring harness at established point.
Strip off insulation from both wire ends.
See repair instructions:
CUTTING TO LENGTH AND STRIPPING OFF INSULATION FROM CABLES .
Crimp contact sleeves on both wire ends.
See repair instructions:
BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION .
Crimp connecting cable for retrofitting likewise with contact sleeve.
Cut required number of poles to length for comb connectors.
Special tool 61 9 041 (hand pliers) in conjunction with 61 9 042 (matrix) are used for pushing contact sleeves onto comb connectors.
See repair instructions:
SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .
Unlock special tool 61 9 041:
Squeeze grips (1) lightly and push release lever (2) in arrow direction.
Or:
Compress handles up to stop, and hand pliers unlock automatically.
Insert prepared comb connectors (3) in special tool 61 9041/61 9042.
Attach wire with contact sleeve to comb connector.
Press hand pliers together and slide on contact sleeve until stop.
Push on further contact sleeves for potential branching.
Installation in wet area (engine compartment, wheel arch):
Apply sealing compound on both sides and press into contacts (1).
Fit heat-shrink tubing and heat up with hot air blower (2) (approx. 250°C).
Do not heat-shrink tubing on edges of comb connector too strongly, risk of cracking.
Allow heat-shrink tubing to cool down until hand- warm. Then press sealing material again into contacts and onto edges of comb connector.
If necessary, carefully heat-shrink tubing again.
Installation in dry area (interior, trunk):
Slide assembled comb connector into insulation housing until it locks into place.
NO RELATED
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.