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(371-1703 UTG. 3) Wiring harness repair kit

TECHNICAL SERVICE BULLETIN
Bulletin Nbr: 371-1703 UTG. 3
Date: ........... OKTOBER 1998
Market: ALL
Wiring harness repair kit


Cars affected

All Saab M94-.

Background

To ensure continued high quality after repairing the wiring harness (especially on cars that must meet with OBDII specifications), a special repair kit has been introduced. The kit contains all the necessary cable terminals and crimp tools. A stripping tool is also included.

Use of the right terminal and the right tool is absolutely essential when carrying out repairs (the part numbers are specified in the spare parts catalogue). The terminals are therefore packed in colour-coded boxes containing a list of contents. The list of contents also indicates the jaw position on the crimp tool that should be used for a particular cable cross-section area. There is also a set of crimp tools, each tool being finished in the same colour as the corresponding terminal box.



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 Wiring harness repair kit, including contact extraction tool 85 80 151

Diagnostic procedure


1. Set the stripping tool supplied with the kit at 6 mm and strip the cable. Check that no strands in the cable are damaged when it has been stripped. If any strands have been broken off or damaged, the end of the cable should be cut off and the cable stripped afresh.


2. Look in the spare parts catalogue for the connector in question to find the part number of the terminal that is to be used.

3. Take out the right terminal, consult to see which box contains the terminal required, and choose the crimp tool having 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.


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 terminal in the crimp tool, as shown, and squeeze the handles of the tool together just hard enough to hold the terminal in position.

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 into the terminal from the left (the labelled side of the tool), see illustration.


7. Crimp the terminal. Note that the crimp tool must be squeezed to its end position before the terminal can be removed.

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



List of terminals and the boxes holding them

























(16) 30 15 427





X





(10) 40 63 939









X

(16) 30 23 819







X



(10) 40 63 970



X







(16) 30 23 835





X





(10) 41 15 077

X









(16) 30 23 843





X





(10) 41 15 085



X







(16) 30 23 850







X



(10) 41 15 275



X







(16) 30 23 868





X





(10) 41 15 481









X

(16) 30 23 892



X







(10) 41 15 499



X







(16) 30 23 900



X







(10) 44 66 728



X







(16) 30 24 015







X



(10) 44 66 801



X







(16) 30 24 023





X





(10) 44 88 201









X

(16) 30 24 031





X





(10) 45 38 005









X

(16) 30 24 049



X







(10) 45 38 062









X

(16) 30 24 056

X









(10) 45 38 856







X



(16) 30 24 064



X







(10) 45 38 872





X





(16) 30 24 072

X









(10) 46 92 257









X

(16) 30 24 106







X



(10) 46 92 505



X







(16) 30 24 122







X



(10) 46 92 612



X







(16) 30 24 130

X









(10) 79 69 256

X









(16) 30 24 148





X





(10) 85 82 413





X





(16) 30 24 155

X









(10) 85 82 603







X

X

(16) 30 24 189





X





(16) 86 12 145



X







(16) 30 24 197







X



(16) 86 12 152



X







(16) 30 24 668







X



(10) 91 20 684



X







(16) 30 24 676







X



(10) 91 20 957

X









(16) 30 25 624

X









(10) 91 22 508







X

X

(10) 40 63 012



X





















Important

Note the type indicator in brackets when ordering.


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 12 137 Stripping tool