Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Wire Splicing: EMEA-Repair
| Refer to REPAIR PROCEDURES INDEX . |
GENERAL INFORMATION
The required repairs are as follows:
- A - Replacement of one or more terminals by cutting the existing cable and connecting a new section of cable with an already crimped terminal.
- B - Replacement of a connector block (housing).
- C - Replacement of a connector assembly (terminal and connector block).
- D - Connecting of two or three cables
- E - Repair of a damaged cable or replacement of a cable section.
The envisaged repairs refer to wires with a cross section up to 4 mm2 . For wires with a section larger than 4 mm2 no repairs are advised; in case of an anomaly in wires larger than 4 mm2 , replace the harness or the entire wiring.
OPERATION CYCLE
The following instructions regard wiring and connector repairs.
A - Replacement of one or more terminals
In order to replace one or more terminals, you need to disconnect the connector block and remove the terminals in question, using the specific extractors in the spare parts case, having part no. 2000042600.
After removing the terminal in question, replace it and make the junction, using the heat seal tube, proceeding as described.
The procedure describes the replacement of a single cable terminal, but is valid for all cable terminals involved in the repair operation.
- Release the cable of the terminal to be replaced from the wiring sufficiently to work with and cut at the midway point as illustrated in Fig. 1.
The section of the electric cable, with a new terminal, must compulsorily have a section that is equal to or slightly larger than that of the cable to be joined. Take care not to get the cables to be joined dirty as this will adversely affect the continuity of electrical conduction.
- Measure the cable that has just been cut (1 - Fig. 2), then cut the new cable section (2) 15 mm longer than the cable to be replaced.
- Strip the new cable section with the cable terminal and the corresponding cable on the cables, for about 13 mm, as shown in Fig. 3.
To avoid cutting the strands and losing part of the cable's conductivity, it is advisable to strip the cables using the suitable wire stripper (A), shown in Fig. 3, available as a Spare Part with part number 2000027100. The length of the strip can be adjusted using the slider (1).
B - Replacement of a connector block (housing)
To disassemble the connector blocks, remove the cable terminals, using the specific extractors available in the spare part case, having part no. 2000042600.
Then insert the terminals of the cables in the same positions they had in the removed connector, insert the gaskets in the unused housings and put back the cable protections.
C - Replacement of a connector assembly (terminal and connector block).
To replace a complete connector, included in the Kit taken from Spare Parts, and the gasket on the cables, using a heat seal tube, proceed as described.
If the cable sections contained in the kit are of the same color, mark the sections consistently with the color of the cables to be replaced.
- Insert the terminals in the connector, with the already crimped cable section, into the same positions occupied in the removed connector and insert the gaskets in the unused housings.
- For a correct junction, make cuts of about 45 mm on the misaligned sections, as shown in Fig. 4, so that it can contain the cable bundle and facilitate subsequent reinsertion into the sheath.
Cut the cables of the new connection consistently with the cables of the wiring, being careful to add 15 mm of overlapping, necessary in order to twist the strands maintaining the correct length of the harness.
D - Connecting of two or three cables
- Junction of two cables (normal and/or Highflex) with a section of less than 4 mm 2
Do NOT perform this procedure on cable sections for the connection of moving parts; for example, between body and tailgate or side doors. For these eventualities, follow the specific procedures.
Proceed with splicing the cables, using the following Fig. 5 as reference.
- Strip the cable terminals, as described above, insert a heat seal tube (1 - Fig. 5), as shown in detail (A), and twist the strands of the cables.
Make sure not to exceed the external diameter of cables, as shown in detail (B).
- Position the sleeve (1) placing the tin ring in the center line of the strands, as shown in detail (C).
- Using a drier fitted with the heat shield tool no. 2000029200 (T) heat the sleeve, as shown in detail (D).
The drier used in this procedure is available commercially whilst the heat shield (T) is a tool having part number 2000029200.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.