Assessment of damage in wiring harnesses - AH00.19-P-1000-05A

Model 124, 126, 129, 140, 163, 164, 168, 169, 170, 171, 199, 202, 203, 208, 209, 210, 211, 215, 216, 219, 220, 221, 230, 240, 245, 251, 414, 461, 463

Always assess the damage thoroughly before repairing the wiring harnesses.

The following criteria must be observed:

Type of damage:

Damage caused by scorching/overheating, chafing, clamping, crushing, severing, fatigue, corrosion, cable chewed by an animal, assembly fault.

Cause of damage:

The cause for the damage must be determined to ensure that the damage does not reoccur after the wiring harness has been repaired.

Scope of the damage:

Which components are damaged, can the damage be identified exactly?
Can you be sure that no other components are damaged?

Repair options:

What are the options for repair?
Which replacement parts are available?

Overview of causes for damage to wiring harnesses

Type of damage:	Possible causes for damage	Possible scope of damage
Scorching/ overheating	Through external overheating: Through contact with hot components (e.g. exhaust system), during welding and soldering, painting and drying work Fire Internal overheating because electric currents are too high: Short circuits at defective components or lines, cable cross-section too small, incorrect fusing (parts not installed correctly or repairs not carried out correctly), short circuits due to bridging (e.g. at wire ends that are not insulated, if insulation is damaged)	Insulation and wires damaged Connector housing deformed Open circuit in wiring Insulated hard and cracked
Chafing, clamping, crushing, severing	Lines routed or secured incorrectly Damage as a result of an accident Damage to cable when boring holes or when screwing sheet metal screws into the body Lines get pinched in clamps or trim parts	Insulation and wires damaged Lines or connections to contacts High line resistance Short circuit to ground and power
Fatigue	Lines routed or secured incorrectly Excessive stress	Open circuit in wiring
Corrosion	Due to contact with acids or aggressive fluids (e.g. brake fluid, antiseize, coolant additives, fuels, lubricants), water penetration due to defective seals, use of high pressure cleaner Wiring harness covered in paint after paint repair Hardening of insulation due to contact with an incompatible agent (e.g. solvent)	Line open circuit, contact pairing not longer conductive (transition resistances) Insulation and wires damaged Lines or connections to contacts High line resistance Components with sharp edges Corrosion
Assembly fault	Use of incorrect tools, e.g. wrong crimper or wrong release tool Damaged contacts or lines through use of unsuitable test tools (e.g. probes) Lines pinched or screwed in	Loose contacts in plug connections Wrong contacts crimped Undesirable transition resistances Open circuit in wiring, short-circuit Insulation damaged

Overview of authorized reworking on wiring harnesses

Type of fault	Remedial action
Faulty contact part
Contact part missing wrong part deformed	Install new contact part
Contact part not engaged properly	Latch contact part, then check, and replace if necessary
Not all individual wires are crimped	Cut off contact part and install new part
Insulation also crimped	Cut off contact part and install new part
Conductor not far enough in contact part	Cut off contact part and install new part
Contact part not tin-plated	Cut off contact part and install new part
Sleeve oxidized wrong part	Cut off contact part and install new part
Not soldered properly/dry solder joint	Resolder contact part and replace if necessary
Plug-in area full of solder	Cut off contact part and install new part
Fault with housing
Screw connections loose	Tighten screw connections using an adjusted torque wrench, replace if necessary
Screw connections wrong part damaged	Install new screw connections (cable connectors)
Coupling housing or plug housing damaged	Install new coupling or housing Check contact and replace if necessary
Coupling housing or connector housing not closed properly	Close coupling or housing properly
Cap screw in handle recess missing loose	Tighten cap screw, replace if necessary
Cable fault
Insulating tubing damaged	Rewrap with PVC tape
Insulation damaged	Cut through affected line at damaged area and repair using Raychem repair method
Insulation pulled up	Cut through affected line at damaged area and repair using Raychem repair method
Wrapping defective	Rewrap
Splashes of solder on cable	Carefully remove splashes of solder using a suitable tool without sharp edges.
Grommet missing wrong part installed incorrectly damaged	Pull on new grommet, or install correctly