Front Wheel Sensor - Replacing Wiring
SECTION3
GROUP
37
NO.
808
DATE
Feb. -96
Replacing wiring to front wheel sensor
800
REFERENCE:
TP 3701201, SECTION 3 (37) WIRING REPAIRS AND REPLACEMENT OF CABLE TERMINAL, 850 900
Replacing wiring to front wheel sensor
The wiring to the front wheel sensor is integrated into the engine compartment wiring. In the past, damage to the wheel sensor wiring has meant replacing the entire engine compartment wiring.
A repair kit with wiring and butt connectors for the front wheel sensor is now available as a replacement part.
Repair kit P/N 9442120-3, contains a wire harness, two moisture proof butt connectors and a transparent tube.
This service bulletin describes the method for replacing wheel sensor wiring using the repair kit.
Method for replacing wire harness to wheel sensor Jack up the car and remove the wheel on the side on which the wiring is to be replaced.
Disconnect wire harness from:
- wheel sensor
- brackets on spring strut and in wheel arch.
- clip on brake line
Connect the new wire harness connector to the wheel sensor.
Secure the wire harness in the brackets on the spring strut, in the wheel arch, and in the clip on the brake line.
The new wire harness is longer then needed for easier routing. Temporarily taping the new wire harness to the old one will make it easier to route it though the engine compartment, and will ensure that its route is the same as the original.
Tape the free end of the new wire harness to the connector on the old wire harness.
Lower car.
Remove the old wire harness from the wheel sensor at its attachment point in the engine compartment between the cable duct and side member.
The routing and attachment of the wire harness varies with model year and variant.
Route the new wire harness into the engine compartment
Pull on the old wire harness until the new one is accessible in the engine compartment. Remove the tape holding the wire harnesses together and route the new wire harness to the cable duct.
Remove the old wire harness
Cut the old wire harness approx. 10 cm (4") from the cable duct.
Secure the new wire harness in the same way as the old one.
Cut the new wire harness approx. 10 cm (4") above the cable duct.
Strip wire harnesses
Use wire stripping tool 951 2641-3 from terminal repair kit 9512647-0.
Strip 19 mm (3/4") insulation
Open the wire stripping tool and position it where the insulation is to be cut.
Twist the tool around a few times to score the insulation. Turning the tool in the Max direction cuts into the insulation deeper than turning it in the Min direction.
Bend the wire several times at the score. Pull off the insulation.
Important:
On the copper wire is a thin, clear layer of plastic. Sometimes this is not removed when the insulation is stripped and can cause faulty signals to the ABS control module.
Scrape the stripped section of wire with a sharp knife. Separate the conductor units and check that no plastic is visible. Twist the conductor units together again before inserting them into the butt connector.
Splice the wiring.
Position the butt connector shrink tube included in the kit on the remainder of the old wire harness.
Splice the wiring from both wire harnesses using the moisture proof butt connectors included in the kit. Note that wires in the same bull connector should be the same color. Use a crimping tool.
The method for splicing wires is described in Service Manual Section 3 (37) Wiring repairs and replacement of cable terminals, 850, 900 section KC.
Protect adjacent components from the heat damage when using a hot air gun.
When wiring is spliced locate the shrink tube over the butt connectors and heat with a hot air gun.
Clamp the wires' excess (which are needed to make the joint) onto the cable duct or existing wire harness. Use electrical tape or a tie strap.
Check that the new wire harness is correctly routed. Secure the new wire harness in the same way as the old one.
Reinstall wheel. Tighten wheel studs alternately to 110 Nm (81 ft.lbs).
WARRANTY STATEMENT: Claims may be submitted under the New Car Limited Warranty when a manufacturing defect is present using claim type: 01
Operation No. Labor description Time allowance
37918-2 Front wheel sensor wiring, replacement 0.7 hr