Assessment Of Damage In Wiring Harnesses - AH00.19-P-1000-05A

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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 extent of the damage be exactly determined?
• 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 authorized reworking on wiring harnesses 

• Contact fault 
  • Contact part missing/wrong/deformed → Replace contact part.
  • Contact part not engaged → Engage, check and replace contact part, if necessary.
  • Individual wires not detected→ Cut off and replace contact part.
  • Insulation also crimped→ Cut off and replace contact part.
  • Cable not far enough into contact part → Cut off and replace contact part.
  • Contact part not tin-plated → Cut off and replace contact part.
  • Sleeve oxidized/wrong → Cut off and replace contact part.
  • Improperly soldered/dry solder joint → Resolder contact part, replace if necessary.
  • Plug-in area full of solder → Cut off and replace contact part.
• Fault with housing 
  • Screw connections loose → Tighten screw connections again using configured torque wrench, replace if necessary.
  • Screw connections wrong/damaged → Replace screw connections (cable connector).
  • Coupling or connector housing damaged → Replace connector or housing.
  • Cap screw in handle recess missing/loose → Tighten cap screw, replace if necessary.
  • Coupling or connector housing not closed exactly → Firmly seal connector or housing.
• Cable fault 
  • Insulating tubing damaged → Rewind 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.

  • Winding faulty → Rewind.
  • Carefully remove splashes of solder on cable using a suitable tool without sharp edges.
  • Grommet missing/wrong/wrongly mounted or damaged → Fit new grommet, mount correctly, if necessary.