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.
61 00... Notes on handling wiring harnesses and cables
The following applies in general:
To avoid damage, observe the following instructions:
- Avoid compressive and tensile loads
- Make sure cables are laid without kinks or abrasions
- Ensure non-contacting routing at sharp-edged body parts; use edge protection if necessary
- Secure additionally laid cables/leads with cable ties
The following additionally applies
Shielded cables
Contact points in the shielding can cause problems with regard to noise radiation and interference immunity. Consequently, distinctions have to be drawn between the following types:
Coaxial cable
- Shielded coaxial cables RTK031 may only be repaired with special crimping tool.
- For aerial lines only the bushing contact may be repaired.
- RG174 Lines and the bushing contact may not be repaired.
CVBS cables
- CVBS cables may not be repaired.
- CVBS cables must be replaced in their entirety.
HSD cables
- HSD cables may not be repaired.
- HSD cables must be replaced in their entirety.
Fibre-optic cables:
- Green = MOST (M edia O riented S ystems T ransport) optical fibres
- Yellow = ISIS (I ntegrated S ervice I nformation S erver) fibre-optic cables
- Orange=repair fibre-optic cables
Attention!
- Fibre-optic cables are permitted to show only one junction point (bridge), replace fibre-optic cables if necessary
- Smallest permissible bending radius is 25 mm
- Avoid effects of heat ≥ 85 °
Treating cables and fibre-optic cables
FlexRay (twisted cables)
It is possible to repair the FlexRay. In the event of damage, the cables can be joined with conventional butt connectors.
- FlexRay lines may only reveal one separation point (bride); renew complete line if necessary.
- If possible, maintain twisted cable after repair.
- After repairs, twist cables as close as possible to the connector/separation point.
- Twisting must be as symmetrical as possible.
Airbag lines:
Repairing airbag cables
Ribbon cables:
Replacement of wiring harnesses:
If after replacing wiring harnesses connectors remain, they should be sealed outside the vehicle interior, for example, with butyl tape so that moisture ingress can be eliminated permanently.
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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.