61 00... Notes on handling wiring harnesses and cables

WARNING: This page is about a different variant/trim than selected.

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 antenna wires only the contact bushing may be repaired.
RG174 Lines and the contact bushing may not be repaired.

CVBS cables

CVBS cables may not be repaired.
CVBS cables must be replaced in their entirety.

HSD lines

HSD lines may not be repaired.
HSD lines must be replaced in their entirety.

Fiber-optic cables:

NOTE: Fiber-optic cables are colored differently as follows:

Green = MOST (M edia O riented S ystems T ransport) optical fibers
Yellow = ISIS (I ntegrated S ervice I nformation S erver) optical fibers
Orange=repair optical fibers

IMPORTANT:

Fiber-optic cables are permitted to show only one junction point (bridge), replace fiber-optic cables if necessary
Smallest permissible bending radius is 25 mm
Avoid effects of heat ≥ 85 °

Working with cables and fiber-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.

NOTE:

FlexRay lines may only reveal one separation point (bride); replace 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:

Repairing 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.