Replacing Wire Harness For Anti-Lock Brake System (ABS)

Replacing Wire Harness For Anti-lock Brake System (ABS)

Tools

Technical values

Preliminary work

Preliminary work on front ABS wire harness
1. Disconnect battery.
2. Remove front wheel housing liner (rear section).
3. Remove plenum panel cover.

Preliminary work on rear ABS wire harness
1. Disconnect battery.
2. Remove rear wheel housing liner.
3. Remove convertible top and water drip pan.

Removing wire harness for anti-lock brake system (ABS)

Removing front ABS wire harness

1. Release the cable retainer -arrow A- and pull off the two connectors -arrow B-.
2. Unscrew the fastening screw and remove the connector socket -arrow C-.

3. Remove the ABS wire harness from the brackets -arrows A-. Removing
4. Open the clips -arrows B- and remove the ABS wire harness -arrow C-.
5. Remove the fabric tape -D-.

INFORMATION: When cutting the ABS wire harness, make sure that there is enough line length left to join to the new lines.

6. Cut off the ABS wire harness around -E- and remove it.

7. Cut through the fabric tape in the plenum panel, in the area around -a-, and expose the remaining ABS lines.

Removing rear ABS wire harness

1. Release the cable retainer -arrow A- and pull off the two connectors -arrow B-.
2. Unscrew the fastening screw and remove the connector socket -arrow C-.

3. Remove the ABS wire harness from the brackets -arrows A-.
4. Open clip -arrow B- and remove ABS wire harness.

INFORMATION: When cutting the ABS wire harness make sure there is enough line length left in the interior to join to the new lines.

5. Cut off the ABS wire harness around -d- and press downward with the rubber sleeve -arrow C-.
6. Cut through the fabric tape at -e- and expose remaining ABS lines.

INFORMATION: Only for vehicles with TPM.

7. Cut through the rubber sleeve at the side of the TPM line -a- and remove the TPM line -arrow B-.

Installing wire harness for anti-lock brake system (ABS)

Installing front ABS wire harness

1. Place socket in installation position -arrow A- and screw on the fastening screw.
Tightening torque: 10 Nm (7.5 ftlb.)

2. Plug in the two connectors -arrow B-.
3. Fold back the cable retainer -arrow C- until it engages correctly at the connectors.

4. Press the ABS wire harness into the supports by pressing on the rubber sleeves -arrows A-.
5. Secure line for headlight levelling system to the ABS wire harness using fabric tape -B-.
6. Place ABS wire harness in installation position -arrows C- and close clip -arrows D-.

7. Push through ABS wire harness to plenum panel -arrow-.

INFORMATION:
- Select a place for the joint where there is enough space to join all the lines present.
- Do not cut the lines too short in case they have to be laid in a different position if there is insufficient space in the area of the joint.
- The electric lines are located in the plenum panel and are thus exposed to the highest demands.
- 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 harnesses NR.155-1.
- Crimping samples are to be prepared before beginning work.

8. Crimp lines in area around -b-.
8.1. Cut off lines in different lengths (due to the shrink-fit connections).
8.2. Slide shrink-fit hoses onto the lines.
8.3. Strip 10 mm of insulation off the wires.
8.4. Crimp lines using crimping sleeves and the hand crimping pliers from the repair kit for harnesses NR.155-1.
8.5. Slide the shrink-fit hoses over the crimp connections and carefully shrink them using the hot-air blower with special nozzle (recommended accessories for the repair kit for harnesses) so that they are watertight.
8.6. Wrap commercially available PVC tape all around the area of the connection points.

9. Secure the repaired area to the neighboring wire harnesses using tie-wraps -c-.

Installing rear ABS wire harness

4. Press the ABS wire harness into the supports on the spring strut by pressing on the rubber sleeves -arrows A-.
5. Insert ABS wire harness into clip and close clip -arrow B-.
6. Push the ABS wire harness inward -arrow C-.

INFORMATION: Only for vehicles with TPM.

7. Cut through the rubber sleeve -a- and insert the TPM line -arrow B-. Stick the rubber sleeve together at the cut edge -a- using a commercially available PUR adhesive and seal.
8. Fit rubber sleeve -arrow C-

INFORMATION:
- Select a place for the joint where there is enough space to join all the lines present.
- Do not cut the lines too short in case they have to be laid in a different position if there is insufficient space in the area of the joint.
- 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 harnesses NR.155-1.
- Crimping samples are to be prepared before beginning work.

9. Crimp lines in area around -a-.
9.1. Cut off lines in different lengths (due to the shrink-fit connections).
9.2. Slide shrink-fit hoses onto the lines.
9.3. Strip 10 mm of insulation off the wires.
9.4. Crimp lines using crimping sleeves and the hand crimping pliers from the repair kit for harnesses NR.155-1.
9.5. Slide the shrink-fit hoses over the crimp connections and carefully shrink them using the hot-air blower with special nozzle (recommended accessories for the repair kit for harnesses) so that they are watertight.
9.6. Wrap commercially available PVC tape all around the area of the connection points.

10. Secure the repaired area -a- to the neighboring wire harnesses using fabric tape.

Subsequent work

Subsequent work on front ABS wire harness
1. Install plenum panel cover.
2. Install front wheel housing liner (rear section).
3. Carry out work instruction after disconnecting the battery.

Subsequent work on rear ABS wire harness
1. Install convertible top and water drip pan.
2. Install rear wheel housing liner.
3. Carry out work instruction after disconnecting the battery.