Campaign - Antitheft Wiring Harness Modification
Section3
Group
37
No.
0019
Year
03
Month
03
Service Upgrade 116
Background
Adjusting the steering column may affect the function of the immobilizer system. The following method will inspect the harness for any damage and change the wire routing to prevent the possibility of future damage.
Material
Special tools
Cables
Cable harness, immobilizer antenna ring, repair
1
Inspection and repair of antenna ring cable harness
Remove the steering column shroud as described in VADIS.
Locate the spring at the right-hand side, in front of the
steering lock, as illustrated. The sharp edge on the end
of the spring may chafe the antenna ring cable harness.
Fit a piece of hose over the spring.
Push the piece of hose about 5-10 mm onto the spring. Cut the
hose about 2 mm from the end of the spring.
Note!
Do not allow the end of the spring to be exposed.
Then inspect the cable harness carefully for damage. If the
harness is damaged, proceed to operation 3.
2
Installing additional protection
If the cable harness is intact, install insulating tape all
the way from the connector to the existing tape approx. 100 mm
along the harness.
Disconnect the harness connector from the antenna ring.
Reposition the cable harness over the key lock cable and
reconnect the antenna ring.
Refit the steering column shroud.
Carry out function control by making sure the engine starts
and that the lighting around the key lock illuminates.
3
Preparations for repair of cable harness
To be performed only if the cable harness is damaged.
Disconnect the battery negative cable as described in VADIS.
4
Assessment of damage
If any of the copper conductors are damaged, proceed directly
to operation 9.
If only insulation, but no conductor, is damaged, disconnect
the antenna ring and mise the secondary lock (1). Continue
to operation 5.
Primary lock
5
Use removal tool 951 2637 to release the primary lock
(see illustration).
Pull the cable gently backward while releasing the lock.
Caution!
Work on only one cable at a time to avoid interchanging
cables.
Fitting the shrink sleeve
6
Slide a shrink sleeve into position, ensuring that it is
positioned equally on each side of the damaged area.
Use hot air gun 951 2850 and nozzle 951 2779.
Set hot air gun to flow 2 and set the temperature between 2 and 3.
Protect the surrounding components from heat. Position the
shrink sleeve in the nozzle and heat so that the shrink
sleeve seals tightly.
Note!
Take care not to overheat the sleeve or wire.
7
Connector reassembly
Check that the locks on the cable terminal are intact. Push
the terminal into the housing. Check that the terminal is
locked in position by pulling gently on the cable.
Repeat the procedure on any other damaged cables. Press the
secondary lock into position.
Apply insulating tape all the way from the connector to the
existing tape about 100 mm along the cable harness. Position
the harness over the key lock cable and reconnect the connector.
Refit the steering wheel shroud.
8
Reconnection of battery negative cable Reconnect the
battery negative cable as described in VADIS.
Carry out function control by making sure the engine starts
and that the lighting around the key lock illuminates.
9
Repairing a damaged copper conductor A damaged copper
conductor can be repaired using a butt joint.
Caution!
Work on only one cable at a time to avoid interchanging cables.
10
Splicing the conductor
Disconnect the connector and cut the conductor at the damaged point.
If the conductor needs to be lengthened, use the same gauge
wire. Strip about 6 mm of the insulation from the conductor
ends.
11
Displacement of joints
Note!
Locate all butt joints with a relative displacement to
each other. There should be no overlap.
12
Crimping the joint
Insert the butt joint in the crimping tool 951 2785 (red opening).
Squeeze the tool slightly and push the conductor into the sleeve
as far as it will go.
Crimp the joint.
Pull gently on the cable to ensure that it is secure.
13
Shrinking the joint
Use hot air gun 951 2850 and nozzle 951 2779. Set the hot air
gun to flow 2 and set the temperature between 2 and 3.
Protect the surrounding components from heat. Position the
butt connector in the nozzle and heat the joint so that
the adhesive melts and begins to emerge from each end.
Take care not to over heat the sleeve or wire.
Note!
Protect the surrounding area from heat.
14
Insulation of cable harness
When all conductors have been repaired:
Apply insulating tape all the way from the connector to the
existing tape about 100 mm along the cable harness.
Position the harness over the key lock cable and reconnect
the connector.
Refit the steering wheel shroud.
15
Reconnection of battery negative cable
While battery is still disconnected, install ignition key and
move to position II.
Reconnect the battery negative cable as described in VADIS.
Carry out function control by making sure the engine starts
and that the lighting around the key lock illuminates.