9-3 (9440) L4-2.0L Turbo (2007)
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Wiring Harness: Procedures
Wiring Harness Repair
Always use 86 12 079 Toolbox, wiring harness, 86 12 483 Toolbox, wiring harness or 86 12 939 Toolbox, wiring harness, for wiring harness repair. In
order to prise the cable terminals out from the connector housings, use Extraction tool 85 80 151. Extraction tool 85 80 151 is included in the kits
numbered 86 12 483 and 86 12 939.
WARNING: Airbag system cables must not be repaired. They are to be replaced in their entirety.
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.
