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Wiring harness repair

Wiring harness repair

Always use 86 12 079 Toolbox, wiring harness or 86 12 483 Toolbox, wiring harness when repairing the wiring harness. Extraction tool 85 80 151 is to be used to extract cable terminals from connectors. Extraction tool 85 80 151 is in kit 86 12 483.

Warning

Cables to the ABS, TC-ABS and airbag systems must not be repaired, they must be changed completely.


A. If cable insulation only is damaged

If the cable is located inside the cabin or luggage compartment: Wind two layers of tape around the cable to cover about two centimetres on each side of the damaged spot.

If the cable is located in the engine bay or underneath the car: Proceed with point 1 below.

B. If a strand of cable has broken or if the cable terminal has come loose:




1. Cut off the cable and strip the end/ends with the cable stripper set on 6 mm. Make sure that none of the strands of cable are damaged while stripping the cable. If any strands have been cut or damaged, the cable must be cut off completely and restripped.

2. Locate the relevant connector or sleeve in the spare parts catalogue/EPC to obtain the part number for the cable terminal/sleeve being used.

3. Locate the correct cable terminal/sleeve, see List of cable terminals/sleeves and in which boxes they are kept for the box containing the relevant cable terminal/sleeve, and select the pliers with the same colour as the box.

Important

Using the right terminal and the right tool is absolutely essential when carrying out repairs. It is also extremely important to ensure that the crimp tools are used only on terminals from the box having the same colour as the tool.


4. Check the cross-section area of the cable to be sure of selecting the right jaw position on the crimp tool. See the list of contents in the box, which indicates the jaw position on the tool that should be used for the cross-section area of the cable in question.


Important

It is extremely important to use the right jaw position on the crimp tool.


5. Place the cable terminal/sleeve into the pliers, see illustration, and clamp together the pliers to secure the cable terminal.

Important

Each jaw position on the tool has two sizes, the large one for insulation strain relief and the small one for the conductor strands.


6. Insert the cable from the left (text side of pliers), see illustration. The strands must be visible on both sides of the cable terminal contact area.


7. When fitting cable terminal: Compress the cable terminal. Note that the pliers must be pressed together fully before the cable terminal can be released.

When fitting a sleeve: Compress the cable sleeve. Note that the pliers must be pressed together fully before the sleeve can be released. Put a shrink tube with adhesive over the sleeve. Fit the cable into the other side of the sleeve in the same manner. Heat the shrink tube over the sleeve.

8. After crimping, the strands of the cable should be visible on both sides of the terminal's contact area, see illustration.



List of cable terminals/sleeves and in which boxes they are kept

RD = Red, GN = Green, YE = Yellow, BU = Blue, BK = Black, OGN = Olive green

Part No. RD GN YE BU BK OGN
(16) 30 15 427





X







(16) 30 23 819







X





(16) 30 23 835





X







(16) 30 23 843





X







(16) 30 23 850







X





(16) 30 23 868





X







(16) 30 23 892



X









(16) 30 23 900



X









(16) 30 24 015







X





(16) 30 24 023





X







(16) 30 24 031





X







(16) 30 24 049



X









(16) 30 24 056

X











(16) 30 24 064



X









(16) 30 24 072

X











(16) 30 24 106







X





(16) 30 24 122







X





(16) 30 24 130

X











(16) 30 24 148





X







(16) 30 24 155

X











(16) 30 24 189





X







(16) 30 24 197







X





(16) 30 24 668







X





(16) 30 24 676







X





(16) 30 25 624

X











(10) 40 63 012



X









(10) 40 63 939









X



(10) 40 63 970



X









(10) 41 15 077

X











(10) 41 15 085



X









(10) 41 15 275



X









(10) 41 15 481









X



(10) 41 15 499



X









(10) 44 66 728



X









(10) 44 66 801



X









(10) 44 88 201









X



(10) 45 38 005









X



(10) 45 38 062









X



(10) 45 38 856







X





(10) 45 38 872





X







(10) 46 92 257









X



(10) 46 92 505



X









(10) 46 92 612



X









(10) 51 08 238







X





(10) 51 08 246





X







(10) 51 08 253

X



X







(10) 53 51 739











X

(10) 53 51 747











X

(10) 53 51 788











X

(10) 53 51 796











X

(10) 79 69 256

X











(10) 85 82 413





X







(10) 85 82 603







X

X



(16) 86 12 145



X









(16) 86 12 152



X









(10) 91 20 684



X









(10) 91 20 957

X











(10) 91 22 508







X

X