SAAB WIS ONLINE

Wiring harness repair kit

SERVICE INFORMATION
Bulletin Nbr: 371-1703 UTG. 2
Date: ........... June 1997
Market: ALL
Wiring harness repair kit


Cars affected

All M94- Saab models.

Background

To ensure high quality when repairing wiring harnesses (especially in cars that must meet OBDII requirements), a special kit has been developed. This kit includes all required cable terminals with required pliers. In addition, a pair of stripping pliers for removing lead insulation is included.

Use of the correct terminal and 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 which 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 correct 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 80 110, for instance. The other compartment can be used for any other suitable equipment.

Parts required

(16) 86 12 079 Wiring harness repair kit

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 again.


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 correct terminal and 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 correct jaw position on the crimp tool. See the list of contents in the box, which indicates the jaw position on the tool which should be used for the cross-section area of the cable in question.


Important

It is extremely important to use the correct 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 their boxes

























(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

When ordering, note the type signal.


Part No. for cable terminal crimp tool

(16) 86 12 020 Cable terminal crimp tool, black

(16) 86 12 038 Cable terminal crimp tool, green

(16) 86 12 046 Cable terminal crimp tool, red

(16) 86 12 053 Cable terminal crimp tool, blue

(16) 86 12 061 Cable terminal crimp tool, yellow

(16) 86 12 137 Cable stripping tool