Procedure
MethodPreparations:
- Disconnect battery negative lead
- Remove wiper arms
- Remove cowl cover from windshield wiper well.
Unscrew and remove central electrical unit cover (4 x torx)
Cut tape on cable duct (at A)
Remove clips holding wire on brake line. Remove wire harness from clip on wiper bracket. Remove screws holding central electrical unit. Lift the electrical distribution unit from its box and place on the edge of the windshield wiper well.
Remove all relays in position 201-215
Reinstall the central electrical unit in its box.
Install one screw to temporarily hold the central electrical unit in place.
Remove wire harness covers
Remove fuse panel (3 screws) Remove rubber grommets Lift the fuse panel to gain access to wires.
Identify two spliced wire pairs (4 wire slices)
2 brown and 2 black wires. (These wires may also be black-white and brown-white)
The wire colors can be as illustrated.
Expose wire splices by pulling them out
Cutting wires
Important:
Only cut one wire at a time so as not to mix them up.
Take great care not to damage other wires. Use good lighting when cutting wires.
One wire splice can be pulled forward relatively easily.
Try to pull the other to the side, in the same direction as the wire harness.
If this is not possible, cut the wire pair as close to the wire splice as possible and pull out sideways. Locate and pull out the other cut wire ends.
Cut wire splice on both wires.
On the 4 wire ends strip insulation 13 mm (1/2") with tool 951 2620.
There may be a thin plastic film residue on the white (tinned) conductor units.
Important:
Separate the stripped wire ends a little and twist them together again. Do the same with all 4 wire ends.
Note:
The (brown/black) wire pairs are twisted around each other. It is important that the twisted wires will be twisted in the same way as earlier, before they will be re-spliced again. They should be twisted approx. 3 turns per 100 mm (4").
Splice the same wires ends that were previously spliced.
Install a crimping sleeve P/N 967777-4 in crimping tool 951 2649, recess "A". (Most easily done on a work-bench).
Apply slight pressure to secure the crimping sleeve in the tool.
Take the crimping tool with crimping sleeve to the car.
Place both wire ends (same color) in the crimping sleeve in the crimping tool. Insert wires in crimping sleeve so that their insulation comes up to but not into the crimping sleeve. Both wires should be inserted from the same direction (parallel). Note: insert wires in the crimping tool on the side without text.
Apply pressure
Check that the crimping sleeve is securely attached.
When one wire pair has been spliced, cut and splice the remaining wire pair.
Set up an exhaust fan by the soldering site.
When both wire ends (brown/brown and black/black) are together, solder the tops of the wire outside the crimping sleeve.
Note:
This operation should only be carried out by an skilled worker with special experience in soldering connections.
Be careful with adjacent wires. Protect if necessary.
Heat the crimping sleeve/conducting unit ends with the soldering iron. Heat properly. Apply solder so that it runs into the crimping sleeve covering the top of the conductor unit.
Install a section of heat-shrinkable tubing on the wire splice.
The heat-shrinkable tubing is intended to provide good electrical insulation.
Install the heat-shrinkable tubing on the wire splice. Use a putty knife as a shield to protect the area from heat. Heat from close range using a hot air gun. Heat the heat-shrinkable tubing quickly to avoid heating up the area around the splice.
It is important to fully shrink the heat-shrinkable tubing around the crimping sleeve. Its ends do not need to be sealed.
Important:
Do not aim the hot air gun at the electrical distribution unit
If necessary set up an additional heat deflector.
Reinstall central electrical unit.
Check that the black central electrical unit box is secured with a screw. (This makes installing the central electrical unit easier.)
Lower the electrical distribution unit into the black box.
Install central electrical unit with 3 screws. Check that all fuses are in place.
Screw clips over wire harness into place.
Remove screw and pull up black box Place it on the edge of the windshield wiper well. Install and tighten the other wire harness cover. (This is easier to do with the black box lifted up.)
Install relays.
Press the black box into place.
It may help to hold the auxiliary cable duct clip out of the way with a putty knife.
Screw screws into place.
Install and screw fuse box cover into place (4 x torx)
Install a tie strap on the auxiliary cable duct instead of the removed tape. (At arrow and at "A") Secure the wire harness to the break line with a clip. Secure the wire harness to wiper bracket with clips as previously.
Finishing:
Install:
- Cowl cover on windshield wiper well
- Wiper arms
- Battery negative terminal
Enter radio code if anti-theft coded radio installed.
Reset clock.
Note:
Lift up fuse box cover. Paint a green dot on the white edge to the integrated relay/fuse box to show that the wire splices have been respliced.
Refer to ABS / TRACS Noise Diagnostics illustration.
After repairs are complete it is important to check the ABS system.
Method:
- Ignition off
- Connect adapter 951 1354-4 to control module connector (wiring side)
see illustration
- Connect break-out box 981 3190-7 to adapter
- Control module disconnected
- Take readings described in the table