Wiring Harness Repair, Including Supplementary Restraint System Firing Circuit Wiring: Notes

CAUTION: Disconnect the battery before commencing the repair of any wiring harness.

The repair is only appropriate where the damage is localised and is not over the full length of the wiring harness. If the damage is end to end then replacing the whole harness should be considered where appropriate. The damaged section of wiring harness must be removed by cutting either side of the damage at a point where the wiring harness retains its original condition. The number of twists in a twisted pair of wires is important to the functionality of the circuit and as such must be maintained. Note the number of twist over the repair length prior to commencing the repair. The same number of twists must reintroduced after completing the repair.

If repairing multiple wires within a harness, stagger the connecting splices and twist the wire between the connecting splice locations. This will minimize the untwisted length and the effect of increasing the diameter of the harness. On no account must the untwisted length exceed 50 mm (2.0 inch) each side of the connecting splice. When each connecting splice repair is completed, cover the splice with a black glue lined heat shrink sleeve. Use an approved hot air applicator to shrink the sleeve until the glue is visible at both ends. Make sure that connecting splice repairs are not located in any dynamic movement area of a harness.

When all wiring harness repairs are complete, the wiring harness must be wrapped in insulating tape and returned as close as possible to new vehicle condition. Make sure the wiring harness follows the original routing and all clips and connectors are secured.

Repairs to SRS firing circuit wiring.

WARNING: Do not use any vehicle with damage to the supplementary restraint system components or wiring harness.

CAUTION: All supplementary restraint system wiring harness repairs must be completed using the approved repair kit only.

The wiring used for a SRS firing circuit repair must be 0.5 mm² (0.00078 inch² ) cross sectional area. Both the male and female sides of the damaged connectors must be replaced. Installation of SRS pre-terminated connectors, cut the wiring harness at a suitable point as close as possible to the damaged connector (destroy the removed connector). Identify the correct new pre-terminated connector from the SRS firing circuit wiring harness repair kit and cut to a suitable length. Install to the SRS firing circuit wiring harness using the connecting splices supplied.

Follow the repair procedure detailed above, taking into account the staggering of connecting splices and the number of twists. The whole repair should then be covered with yellow heat shrink sleeve supplied to act as SRS firing circuit wiring repair location/identification. The repair authentication label must be completed by the authorized technician conducting the repair and approved by their supervisor. The label must then be secured around the harness adjacent to or at a suitable point as close as possible to the location of the repair.

Care and neatness are essential requirements in making a perfect repair .

CAUTION: Under no circumstances should repair be attempted to the following:

Link lead assembles, which are unique to safety critical circuits such as ABS and thermocouple circuits. An example of this is the ABS wheel speed sensors with moulded connectors.
Throttle Control circuits.
Speed Control circuits.
Screened cables, leads and wiring harness(s).

If any harness(s) with defective electrical connector terminals or cables from the above circuits give cause for concern, new components must be installed.

CAUTION:

Do not attempt to repair or reform a damaged electrical connector terminal. A damaged electrical connector terminal must be replaced using the correct pre-terminated lead.
A ground point connector with multiple wires to the connector must not be repaired as a complete connector. If a damaged wire is identified, the wire can be repaired individually using the correct pre-terminated lead.
Do not attempt the repair of damaged battery, hybrid and power cables.
These types of cable generally have a cross sectional area larger than 6 mm² (0.009 inch² ) and must only be replaced. If the original cable is contained within the harness bundle the original cable must be left in the harness. Attach the replacement cable to the harness along the original harness route.

The replacement cable must follow the original cable route to avoid the risk of introducing electrical interference issues. The original cable connections must be cut from the cable at both ends and discarded. The exposed cable ends must be free from sharp edges and strands of wire. The exposed cable must be over taped to prevent injury before being taped back to the main harness.

If any harness(s) with defective electrical connector terminals or cables from the above circuits give cause for concern, new components must be installed.