Body - Convertible Top Wiring Harness Repair
C701998-2004
Section
8
Group
83
No.
0045
Year
2004
Month
10
Vehicles involved: Convertible
Check and repair of the wiring harness
Background:
This Service Bulletin describes how to check and repair the wiring harness..
Competence requirement:
Volvo Level 3 Technician
Wiring harness check
Preparatory work 1
Soft top setting
Set the soft top to the position illustrated. If the soft top cannot be operated, see:
Repair and Installation
Section Doors and Hatches
Convertible Systems
Wiring harness check 2
Check the routing of the wiring harness at the fold line in the centre of the right-hand side of the roof.
Note!
The wiring harness should not lie against the soft top arch or the joint system.
If the wiring harness is damaged, continue at step 4.
Securing the wiring harness 3
If there are no major damages to the wiring harness, make sure that the wiring harness is taut at the folding line.
Then check that the wiring harness does not lie against the arch or the joint system when the soft top is fully closed.
Installation
Wiring harness repair 4
If there is visible damage to any of the copper leads, do not repair the leads right where the damage lies. Splice a 15 - 20 cm piece of lead to the wiring harness so that the joint sleeves used for the repair do not end up right in the folding line of the soft top. See illustration.
Splicing the lead 5
Detach the connection from the battery's negative terminal.
Open the velcro fasteners and pull the wiring harness forward so that you are able to work.
Remove the insulation tape approx. 10 cm on both sides of the protective sheath. Cut off the damaged lead approx. 8cm on both sides of the damage.
Insert a new lead through the protective sheath and cut to a suitable length. Splice the lead together using two joint sleeves.
For lead splicing, see:
First select S80
Repair and Installation
Section Leads and Fuses
Leads.
Note!
If several leads are damaged, work with one lead at a time to reduce the risk of confusion. Overlap the joints so that the do not lie parallel.
Assembly
Wiring harness assembly 6
Once all leads are repaired, place the protective sheath in front of the folding line, affix insulation tape and secure the protective sheath at both ends as illustrated. Properly position the wiring harness and refit the velcro fasteners.
Finishing
Securing the wiring harness 7
Stretch out the wiring harness.
Make sure that it does not lie against the arch or the joint system when the soft top is fully closed.
Reconnect the negative lead of the battery Set the time in the combined instrument panel and enter any radio code.
WARRANTY STATEMENT:
Claims may be submitted under the New Car Warranty when there is a documented customer complaint, using claim type 01.