Air Bag Systems: Service and Repair

NOTE: When repairing wiring, replace either the wiring harness or the connector. If the wiring harness has been damaged, replace the whole wiring harness assembly. If only the connector has been damaged, then replace the connector as described.


Whenever repairing wire, always use the special repair wire made specifically for this operation, (Part No. 82988-50010).
1. Disable airbag system as described under Technician Safety Information.
2. Remove connector from sensor, then open rear of connector and expose wires. Cut wires behind connector housing, leaving long strands for easier repair.






3. Strip away 0.31-0.43 inch from each wire end. Overlap two stripped pieces of wire and place in pressure sleeve, Fig. 1.
4. Crimp pressure sleeve closed at the center.
5. Once crimped, pull at both ends of wire to ensure tight close.
6. Crimp both of the outside edges of the pressure sleeve.
7. Wrap repair with silicone tape.






8. Wrap ends of corrugated tube with silicone tape, then wrap tube with vinyl tape. The final repair should look as in Fig. 2.
9. Rearm airbag system as previously described.