Operating Procedures For Repairs

Proceed as follows

Using the information below most housings can be opened and the cable terminals replaced. Note that the stages in the operations can be used with most housings/cable terminals and that the illustrations only show a few individual types as examples. Other types can occur. The basic instructions for the repair/replacement of cable terminals are only a summary of the contents, with references to respective operations.

CAUTION: Note the contents, of these instructions must be followed before carrying out any repair work.

WARNING: SRS No cable repair or other repair work may be carried out on the SRS wiring. For repairs to the SRS system refer to the instructions in the Restraint Systems.

Basic procedures for repair operations
Opening a connector
Separate the connector







If the connector halves are connected they must first he opened.

CAUTION: Never pull the cables when opening the connector. Hold the connector halves.

Open the housing
Secondary locking







Opening a housing's secondary locking.

Select terminal removal tool







Select the terminal removal tool that matches the housing's cavity openings.

Remove the cable terminal from the housing
Use the recommended terminal removal tool and follow the operating procedure described.

Select a new cable terminal







Select a new cable terminal of the same type as the existing terminal. Use the cable terminals in the repair kit p/n 981 4235. Refer to the wiring diagram for information on the cable area.

SWS (Single Wire Seal)
Seal sws and plug







If a seal is to be used on the cable terminal thread the seal on to the cable before stripping the insulation on the cable.

Strip the cable







Cut and strip the cable to a length that matches the cable terminal.

Select a suitable crimp tool for the cable terminal







Refer to information on which tool is used for which type of cable terminal.

Crimp the cable terminal

Place the cable terminal in the crimp tool jaws, in the profile that matches the cable area of the cable. Position the cable in the cable terminal. Crimp the cable terminal on to the cable end.

Checking crimping of a cable terminal

Checking the result of the crimping operation







Always check the result of the crimping operation and that the primary locking is not damaged.

Insert the cable terminal in the housing






Insert the cable terminal in the appropriate cavity until the primary locking activates.
Check that the cable terminal is properly locked by pulling lightly on the cable.

Close the housing







The housing's secondary locking must be closed.