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 - CABLE FIGURE 2 below ), 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 CABLE FIGURE 3 below , 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 CABLE FIGURE 4 below , 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 CABLE FIGURE 5 below as reference.
- Strip the cable terminals, as described above, insert a heat seal tube (1 - CABLE FIGURE 5 below ), 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.
Extremely high temperatures are reached while heating the thermal shrinking sleeve. Accordingly, the heat shield must not, under any circumstances , come into contact with parts of the body or the vehicle. This presents a risk of burns to the body and risk of fire.
- The sleeve (1) must be heated until the adhesive rings (2) stick to the cable, for a perfect sealing and the tin ring (3) melts, welding the coupling, as shown in detail (E).
Heat the tube with the utmost care so as to avoid damage and loss of watertight. WAIT FOR THE TUBE TO COOL DOWN before handling the splicing.
| 1 - | Heat shrinking solder sleeve |
| 2 - | Adhesive-rings |
| 3 - | Tin ring |
| 4 - | Heat shield - Tool no. 2000029200 |
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.
- Insert the cables connected inside the corrugated sheath and/or protect the junction segment using insulating tape.
- Junction of three cables (normal and/or Highflex) with a section of less than 4 mm2
- Strip the cable terminals, as described above, insert a heat seal tube (1 - CABLE FIGURE 6 below , and twist the strands of the three cables as shown.
Make sure to contain as much as possible the external diameter of the strands, as shown.
| 1 - | Heat shrinking solder sleeve |
Place the sleeve (1 - CABLE FIGURE 7 below ) until the splice is covered: the tin ring (3) should go next to the joined strands, as shown.
| 1 - | Heat shrinking solder sleeve |
| 2 - | Tin ring |
Extremely high temperatures are reached while heating the thermal shrinking sleeve. Accordingly, the heat shield must not, under any circumstances , come into contact with parts of the body or the vehicle. This presents a risk of burns to the body and risk of fire.
Heat the tube with the utmost care so as to avoid damage and loss of watertight. WAIT FOR THE TUBE TO COOL DOWN before handling the splicing.
- Using a drier with heat shield tool 2000029200 (T) heat the sleeve (1 - CABLE FIGURE 8 below ).
- The sleeve (1) must be heated until the tin ring (3) melts, welding the splice, and the adhesive rings (2) stick to the cable.
| 1 - | Heat shrinking solder sleeve |
| 2 - | Adhesive-rings |
| 3 - | Tin ring |
| 4 - | Heat shield - Tool no. 2000029200 |
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.
- Insert the cables connected inside the corrugated sheath and/or protect the junction segment using insulating tape.
- "Terminal" junction of three cables (normal and/or Highflex) with a section of 4 mm2
- Strip the cable terminals for about 13 mm, as shown above, and twist the strands, as shown in CABLE FIGURE 9 below
Align the winding slightly pointed, with an external diameter as small as possible, as shown in detail (A).
To ensure the supply of the correct amount of tin and ensure the correct continuity of electrical conduction, you need to preemptively make a welding using tin, as shown in detail.
- Insert the winding of the strands (A - CABLE FIGURE 11 ) to the bottom of the heat seal tube (1), as shown in detail (B).
Make sure that the winding of the strands can be inserted inside the copper spiral (S) which can be seen inside the tube (1) and that the tin ring is on the center line of the junction, as shown in detail (B).
- Using a drier fitted with the heat shield tool no. 2000029200 (T) heat the sleeve, as shown in detail (D -CABLE FIGURE 12 ).
The drier used in this procedure is available commercially whilst the heat shield (T) is a tool having part number 2000029200.
Extremely high temperatures are reached while heating the thermal shrinking sleeve. Accordingly, the heat shield must not, under any circumstances , come into contact with parts of the body or the vehicle. This presents a risk of burns to the body and risk of fire.
Heat the tube with the utmost care so as to avoid damage and loss of watertight. WAIT FOR THE TUBE TO COOL DOWN before handling the splicing.
- The sleeve must be heated until the sealing rings stick on the cables and the tin ring melts, welding the coupling.
| 1 - | Heat shrinking solder sleeve |
| T - | Heat shield - Tool no. 2000029200 |
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.
- Insert the cables connected inside the corrugated sheath and/or protect the junction segment using insulating tape.
- Junction of two cables (normal and/or Highflex) with a section of 4 mm2
Proceed with the junction of the cables (normal and/or Highflex) with a section of 4 mm2 , referring to CABLE FIGURE 13 below.
- Strip the cable terminals, as described above, fit a thermal shrinking solder sleeve (1 - CABLE FIGURE 13 below ) having the right section and divide the cable strands, without twisting them, as shown in detail (A).
- Join the two cables and twist the strands, as shown in detail (B).
Make sure not to exceed the external diameter of cables, as shown in detail (B).
To ensure the supply of the correct amount of tin and ensure the correct continuity of electrical conduction, you need to preemptively make a welding using tin, as shown in detail.
- Position the sleeve (1) placing the tin ring in the center line of the strands, as shown in detail (D).
- Using a drier fitted with the heat shield tool no. 2000029200 (T) heat the sleeve, as shown in detail (E).
The drier used in this procedure is available commercially whilst the heat shield (T) is a tool having part number 2000029200.
Extremely high temperatures are reached while heating the thermal shrinking sleeve. Accordingly, the heat shield must not, under any circumstances , come into contact with parts of the body or the vehicle. This presents a risk of burns to the body and risk of fire.
Heat the tube with the utmost care so as to avoid damage and loss of watertight. WAIT FOR THE TUBE TO COOL DOWN before handling the splicing.
- The sleeve (1) must be heated until the adhesive rings (2) stick on the cable, for a perfect sealing and the tin ring (3) melts, welding the coupling, as shown in detail (F).
| 1 - | Heat shrinking solder sleeve |
| 2 - | Adhesive-rings |
| 3 - | Tin ring |
| T - | Heat shield - Tool no. 2000029200 |
- Insert the cables connected inside the corrugated sheath and/or protect the junction segment using insulating tape.
E - Repair of a damaged/broken cable (normal or Highflex) or replacement of a cable section
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.
If a cable is broken or damaged, repair it or fit a section of repair cables, proceeding as described.
In order to repair a broken or damaged cable, it is necessary that the cable can be overlapped for about 15mm, without causing tension or damaging the size of the harness.
- Remove the cable to be repaired from the cable bundle or from the corrugated sheath, as described above, for about 13 mm, as shown in CABLE FIGURE 14 .
- Fit a heat seal tube (1 - CABLE FIGURE 15 ), overlap the cable terminals and twist the strands, as shown.
Make sure not to exceed the cable outside diameter, as shown.
- Then make the junction, proceeding as described above.
| 1 - | Heat shrinking solder sleeve |
If the cable that needs to be repaired cannot be overlapped, you need to fit a 150 - 200 mm long cable section (2 - CABLE FIGURE 16 ), which should have the same section.
- Cut the cable to repair (1), ensuring an overlapping, on both sides for about 13 mm, as shown.
- Fit two heat seal tubes; overlap the terminals of the cable and twist the strands.
Make sure not to exceed the cable outside diameter, as shown in detail.
- Then make the junction, proceeding as described above.