(371-1703 UTG. 4) Wiring harness repair kit

/ 9-3 (9400) / 1998 / 3. Electrical System / Wiring harness / Bulletins - SI/MI / (371-1703 UTG. 4) Wiring harness repair kit

SERVICE INFORMATION
Bulletin Nbr:	371-1703 UTG. 4
Date: ...........	JANUARY 2001
Market:	ALL

Wiring harness repair kit

Cars affected

All M94- Saab models.

Background

In order to ensure good quality repairs of the wiring harness, a special repair kit has been introduced. This kit contains all the relevant cable terminals and sleeves with associated pliers. A cable stripper is also included.

It is absolutely essential to use the correct cable terminal or sleeve and pliers for repairs (the part number can be found in EPC). The cable terminals and sleeves are therefore packed in colour-coded boxes with list of contents. The list of contents also specifies which pliers setting to use for the respective cable area. There is also a set of cable terminal pliers in the same colours as the boxes.

In order to repair OnStar and telephone connections from M01, a new cable terminal pliers with associated cable terminal box has been introduced as a complement to cable repair kit (16) 86 12 079 / (16) 86 12 483. The pliers and cable terminal box are olive green.

Important
It is extremely important to ensure that the crimp tools are used only on terminals from the box having the same colour as the tool and that the right jaw position on the tool is used, as indicated by the list of contents in the box. That is because a mere hundredth of a millimetre can make all the difference between a good result and a poor one.

In addition to these boxes and tools, the case also contains two external compartments. One of these compartments can be used for storing contact extraction tool 85 80 151, for instance. The other compartment can be used for any other suitable equipment.

Parts required

(16) 86 12 079 Wiring harness repair kit

(16) 86 12 483 Repair kit, wiring harness, including extraction tool 85 80 151

The present stock of repair kits has been updated. Owners of the repair kit must order the new cable terminal pliers and cable terminal box separately as they are not supplied according to tool subscription A 2 / 4.

(16) 86 12 632 Cable terminal pliers, olive green

(16) 86 12 665 Cable terminal box, olive green, including laminate and cable terminals

Procedure

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 compartment 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:

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.

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

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
Use of 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.

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.

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.

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.

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 terminal. 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.

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

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 number	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

Part numbers for crimp tools

(16) 86 12 020 Crimp tool, black

(16) 86 12 038 Crimp tool, green

(16) 86 12 046 Crimp tool, red

(16) 86 12 053 Crimp tool, blue

(16) 86 12 061 Crimp tool, yellow

(16) 86 12 632 Cable terminal pliers, olive green

(16) 86 12 137 Stripping tool

(371-1703 UTG. 4) Wiring harness repair kit

A. If cable insulation only is damaged

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

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