Repairing Main Wire Harness At Door Connection Point

Information 

Use the following repair kit for carrying out repairs at the door connection point.

• Repair kit for wire harness for door connection point, Part No. 000.043.303.33 

1. Replace wire harness at the door sub-frame -1-  . → 973219 REMOVING AND INSTALLING WIRE HARNESS FOR DOOR 
   Fig 1: Identifying Installation Position Of Wire Harness For Front Door

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   1. Wire harness on door sub-frame
   2. Wire harness in door panel
2. Disconnect connector for door connection point at the A-pillar.
   Fig 2: Disconnecting Connector For Door Connection Point

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   1. 2.1. Open primary lock -1-  (-arrow a-  ).
   2. 2.2. Release locking lugs -arrows b-  and press connector for door connection point -2-  into the passenger compartment -arrow-  .
3. Unscrew fastening nut -1-  on the ground strap and remove the ground straps -2-  together with the twist lock at the ground point (for easier access to the connector at the door connection point).
   Fig 3: Disconnecting Ground Straps

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   Information 

   Select a place for the joint where there is enough space to join all the lines present.

4. Remove binding tape -1-  from around the wire harness over a width of approx. 5 cm and disconnect the lines -2-  from pin 10 -(A)-  and pin 11 -(B)-  of the wire harness.
   Fig 4: Identifying Wire Harness

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5. Open secondary lock on the connector for the door connection point -arrow-  .
   Fig 5: Opening Secondary Lock

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   If necessary, mark the electric lines.

   For allocation, see wiring diagram (depending on the model year)

   Information 

   The greatest care must be used in the individual work steps for stripping insulation from, crimping, and shrinking/insulating the electric lines.

   The procedure for stripping insulation from, crimping, and shrinking/insulating the electric lines must be complied with and observed. The procedures are described in detail in the Repair Kit For Wire Harnesses NR. 155-1  .

6. Prepare contacts on connector for door connection point.
   Fig 6: Pressing Out Contacts On Connector For Door Connection Point

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   1. 6.1. Unpin the lines at pin 10 -A-  and pin 11 -B-  from the connector for the door connection point.
   2. 6.2. Cut the lines at an offset position in the marked area.
7. Connect lines from the connector for the door connection point to the repair lines from the repair kit, Part No. 000.043.303.33.
   Fig 7: Crimping Lines For Connector For Door Connection Point

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   1. 7.1. Crimp insulated cable connection -1-  using the crimping pliers  from the repair kit for wire harnesses  to the original lines for the door connection point -2-  .
   2. 7.2. Slide shrink-fit hose -3-  onto the lines -2-  .
   3. 7.3. Crimp new lines -4-  from the repair kit to the insulated cable connection -1-  using crimping pliers  . Check the crimp connection carefully.
   4. 7.4. Slide shrink-fit hose -3-  over the crimp connection and carefully shrink it using the hot-air blower with spoon strainer attached  so that it is watertight.
   5. 7.5. Insert new lines -4-  into the connector for the door connection point at pin 10  and pin 11  until the contact engages securely.

   When doing this, check that the line from pin 10 and pin 11 is inserted into the original connector socket.

8. Close secondary lock on the connector for the door connection point -arrow-  .
   Fig 8: Closing Secondary Lock On Connector For Door Connection Point

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9. Wrap binding tape around the wire harness again and cover the new lines -1-  with fabric tape -2-  .

   The crimps -3-  must be positioned in several steps so that they are not lying on top of each other.

   Fig 9: Routing Lines For Connector For Door Connection Point

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10. Plug connector for door connection point -1-  into the A-pillar -arrow a-  and lock the primary lock -2-  (-arrow b-  ).
    Fig 10: Securing Connector For Door Connection Point

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11. Fit ground straps -2-  together with the twist lock onto the stud for the ground point -arrow-  and secure with the fastening nut -1-  . → Tightening Torque: 9 Nm (6.5 ft. lb.) 
    Fig 11: Screwing Fastening Nut To Ground Point

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