Wiring Harness and Connector Repair

CAUTION: Before attempting diagnostic prove out, check for wiring shorts that could cause the diagnostic monitor to blow the air bag battery feed fuse, causing unnecessary servicing.

Inspect the sensor wiring and the wiring harness for any damage that may have occurred due to the collision. Replace any damaged wiring, terminals, insulation or connectors, as required.

If splices are required in adjacent wiring. Splices should be staggered 50mm (2 inches) apart from each other. Service as follows:





1. Correctly strip the wires.

NOTE: A durable splice is a 5-step process to be used for 16 gauge wire and smaller. For larger than 16 gauge wire, a jiffy splice must be used.





2. Twist and solder the wire (don't forget to install the shrink tubing first). Use rosin core, mildly activated (RMA) solder. (Do not use acid core.)

NOTE: Durability of a wire splice is dependent on getting a joint that does not oxidize. Soldering is effective in keeping the air (oxide) out of the joint. Electronic circuits, and the very high current circuits, may fail because of oxidized joints. Oxidation cannot be seen with the naked eye.




3. Form (bend) the circuit into a shape for sealing as illustrated.




4. Reposition the shrink tubing over the splice.




5. Heat the entire length of the shrink tubing until the "hot sealant" comes out of both ends.

NOTE: When the "hot sealant" flows out of both ends of the tube it has been heated long enough.



CAUTION: Use a heat gun only. Do not use a hair dryer or any flame to heat the shrink tubing. Durability of a splice is dependent on keeping the moisture out of the joint. The heat shrink tubing alone won't do the job. The tubing must contain a "hot melt sealant" which is squeezed from both ends of the tube during heating and forms an adhesive seal between the cable and the tube.