SRS (Supplemental Restraint System) Cable Harness, Repair
Open the cover
Install the new cover
Then locate hinge (B)
The numbering of the connector terminals is illustrated opposite
Replacing cable terminals
SRS (Supplemental Restraint System) Cable Harness, Repair
Cable harness
Repairs
A special procedure has been developed for repairing the SRS cable harness. The SRS system is extremely sensitive. If all steps in this procedure are followed we can guarantee that repairs will be just as good as those on the wiring in ordinary systems.
NOTE: These instructions must be followed whenever carrying out work on the cable harness for the SRS system.
The following tools and equipment must be used to guarantee that work is of the highest quality.
- Press tool
- Cable stripping tool number 951 2620
- Repair kit, P/N
- Hot-air gun, P/N 951 2777
- Nozzle kit for the hot-air gun, P/N 951 2778.
NOTE: The cable harness must always be connected by color. A colored cable to a colored cable or a multi-colored cable to a multi-colored cable.
Repair points
NOTE: Cables must not be spliced in the car except in the specified places.
The cable harness must not be spliced in the car except in specified places:
A-post
- Remove
- the front floor carpet.
B-post
- Remove
- the front floor carpet.
- the rear floor carpet.
- the B-post panel.
C/D-post
- Remove
- the rear seat assembly.
steering column duct
- Remove
- the soundproofing panel.
and by the side of the heater unit
- Remove
- the dashboard.
Preparations
- Note when disconnecting/connecting the battery lead
- Igniter wire connector.
Inserting and cutting the cable harness
Disconnect the connector and connect the new connector. Route the cable the same way as the existing cable to the splice point (either on the inside or along the outside of the cable duct/cable harness. Check that the cable is not too short or too long. Cut the cable. Remember that the splice itself will require some length of cable.
NOTE: It is essential that the cable is the correct length.
Cut off the old and new cables at the points shown.
NOTE: Do not damage any other wiring when cutting the cable.
Twin the cable
Twin 60 mm (2-3/8-inch) of the new and the old cable
NOTE: The maximum twinned length after splicing is 100 mm. This is to prevent interference problems (ECM).
Slide on the heat-shrink tubing
Cut and thread at least 80 mm (3-9/64 inches) of the heat shrink tubing on to one side/end of the cable.
Cut and strip the cables
Cut the cables so that there is 40 mm (1-1/2 inch) between the splices (center to center).
NOTE: Do not damage any other wiring when cutting the cable.
Strip the insulation on the 4 cable ends 5.0 mm (13/64 inch). Use pliers 951 2620.
Twin the cable cores on the stripped ends of the cables. Do not forget to carry this out on all four cable ends.
NOTE: Ensure that all the cores are twinned.
Splice the ends of the cables of the same color (single colored or striped)
NOTES:
- The cable harness must always be connected by color. A colored cable to a colored cable or a multi-colored cable to a multi-colored cable. Under no circumstances must the wiring be connected incorrectly. Always a color to a color.
- If the wiring is connected incorrectly the signal to the airbag or tensioner may be weakened and the SRS function may be degraded or disabled. There is a risk of personal injury if the incorrect procedure or tool is used.
Install crimping sleeve 951 2783 in the press tool 951 2785 in the "Green" cut-out. Squeeze the crimping tool a little to secure the crimping sleeve in the tool.
NOTE: That the sleeve is in the correct cut-out in the press tool: the "Green" position.
Insert both cable ends in the crimping sleeve in the tool. Insert the cable as far into the crimping sleeve as it will go. Ensure that the cable insulation does not get into the crimping area and that stripped cable does not extend outside the sleeve.
Secure the crimp-/butt connector.
Press the pliers handles as far as they will go to ensure a proper joint. The pliers release automatically.
Check by hand that the crimping sleeve is secure.
Check that dimension B is 40 mm (1 1/2 inches) between the splices (center to center).
NOTE: Remember that wiring must always be connected by color. A colored cable to a colored cable or a multi-colored cable to a multi-colored cable.
When the first joint has been spliced and checked, splice the other cable ends in the same way.
Heat the heat-shrink tubing
The heat-shrink tubing is intended to provide good electrical insulation.
Hold a putty knife behind the heat-shrink tubing to shield the surrounding components from heat.
Hint: Set the airflow switch for hot air gun 951 2777 to position 2 and the temperature setting potentiometer between positions 2 and 3.
Heat the sleeve using hot air gun 951 2777 and a suitable nozzle. Heat the heat-shrink tubing quickly to avoid heating up the area around the site. It is important that the heat-shrink tubing is shrunk around the cable. It must be sealed at both ends.
NOTE: If necessary, set up a heat deflector.
Heat the heat-shrink tubing
Pull the heat-shrink tubing over the cable splice.
Ensure that the heat-shrink tubing stretches over the outer cable insulation equally on each side.
Heat using a hot air gun to seal the heat-shrink tubing around the repair site at both ends.
NOTE: Use a heat deflector.
Reinstalling and checking
Check the connector.
Check that the cable is secure and not stressed at any point.
Secure the new cable harness to the SRS cable harness (outside the existing cable harness).
If necessary secure the cable using a cable tie, tape or foam rubber to avoid noise.
Hint: Panel, B-post, replacing. Igniter wire connector (ignition key in position II and connect the battery).
Check and fault-trace the new cable section.
Reinstall other components.