Service
Replace affected door wiring harness and install interior wiring repair harness at A-pillar or B-pillar as follows:- Review and heed Repair Manual Cautions and Warnings regarding electrical repairs.
Parts required:
^ Part No: 8Z0971029L (repair harness used for A-Pillar and B-Pillar repairs).
^ Part No: 8E1971029C (left front door harness). Use only if condition exists on left front door.
^ Part No: 8E1971029G (right front door harness). Use only if condition exists on right front door.
^ Part No: 8E0971687E (left or right rear door harness). Use only if condition exists on rear door.
^ Crimp connectors from VAS 1978 Wiring Harness Repair kit.
CAUTION!
Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information.
Door harness, replacing
- Note and if necessary, determine radio code for vehicles equipped with coded anti-theft radio.
- Disconnect battery Ground (GND) strap.
- Remove door panel at affected door, (see Repair Manual, Front door trim, removing and installing or Rear door trim, removing and installing, Repair Group 70).
- Disconnect door wire harness at affected door pillar and remove door wire harness from door.
- Install new door wire harness.
- Reinstall door panel (see Repair Manual, Front door trim, removing and installing or Rear door trim, removing and installing Repair Group 70).
Prior to splicing repair harness review the following:
Wiring repair, general procedures
- Refer to SSP971003 Wiring Harness Inspection and Repair for more information.
- Review instruction manual included in VAS 1978 wiring repair kit.
- If supplemental wiring terminals or supplies are required, use only materials from the VAS 1978 kit.
Wiring, making splice connections
^ Hold repair harness connector next to factory wiring connector (as vehicle wiring may vary in coloring from vehicle to vehicle or pillar as compared to the overlay harness).
^ If wires are twisted on interior wire harness, make sure to twist wires from appropriate pins on connector of repair harness.
^ When required, strip wiring ends using the VAS 1978/3 wire stripper (this minimizes possibility of broken wire strands).
^ All wiring splice connections MUST be made using the VAS 1978/1 crimping tool with the appropriate die for connectors used.
^ Stagger crimped connections to maintain a flexible and compact harness.
^ All wiring splice connections MUST be heat shrunk and sealed using the hot air blower from the VAS 1978 kit and the VAS 1978/15 adapter.
^ Maintain same harness length from connector to interior harness.
^ The repair harness is made to fit models with various equipment levels. Any unused wires should be folded and taped back into the harness (Refer to Unused wiring, taping back to harness).
Unused wiring, taping back to harness
ALL unused wires in the vehicle must be terminated using a cut, stretch, fold, and tape technique as follows:
This prevents unused wires from coming in contact with ground or any other circuit.
- Cut wires with suitable wire cutters.
- Stretch (pull) wire insulation with pliers to extend slightly beyond end of wire strands.
- Fold wire over upon itself.
- Tape wire using vinyl tape.
Front door (Left or right) A-pillar harness, repairing
- Remove Lower A-pillar/sill panel trim (see Repair Manual, lower A-pillar removing and installing, Repair Group 70).
- Disconnect interior wire harness at A-pillar and pull harness back into vehicle.
Note:
Wire colors may not match between interior wire harness and repair wire harness: 8Z0 971 029L. Individual circuits must be matched before wires can be spliced.
Wire harnesses, preparing for splicing
Prior to splicing the repair harness, prepare interior and repair harnesses as follows:
- Remove electrical tape from harnesses.
- Remove contact housing covers -arrow- to expose terminals on harnesses so that individual circuits can be traced and matched (wire for wire) during splicing process.
Interior wire harness, splicing to repair harness
Using VAS 1978, splice all circuits from interior wire harness to repair wire harness.
- Lay connectors side by side and trace each wire out away from connectors in pairs (i.e. wire from first position of repair harness and wire from first position of factory harness).
- Start by splicing twisted wires first.
- Cut original wires from factory interior harness (ONE AT A TIME) and reattach (splice) to wire from same position on connector block of repair harness.
- Continue splicing wires (stagger splices) until all wires from interior harness are connected to the repair harness.
With all wires from interior harness spliced to the repair harness:
- Fold and tape any unused wires (on repair harness) back to harness (Refer to Unused wiring, taping back to harness).
- Reinstall contact housing cover and re-tape wire harness.
- Install repair wire harness connector to A-pillar.
- Lubricate contact housing terminals with anti-corrosion grease, Part No: G 0521 74.A1
- Reconnect door wire harness connector to A-pillar connector.
- Reconnect battery Ground (GND) strap.
- Test all door electrical functions.
- Reinstall lower A-pillar / sill panel trim (see Repair Manual, lower A-pillar trim removing and installing, Repair Group 70).
- Connect the VAS 5051 diagnostic tool.
- Check and erase any stored DTC's.
- Program radio station presets it necessary.
- Check vehicle equipment (radio code, clock, electrical windows) as per Repair Manual and/or Owner's Manual.
Rear door (left or right) B-pillar harness, repairing
Partially remove upper B-pillar trim.
Remove lower B-pillar trim.
Disconnect interior wire harness at B-pillar.
- Remove interior wire harness from plastic harness guide (arrow) and pull harness back as shown.
With harnesses prepared for splicing (see Wire harnesses, preparing for splicing):
- Lay connectors side by side and trace each wire out away from the connectors in pairs (i.e. wire from the first position of the repair harness and wire from the first position of the factory harness).
- Start by splicing twisted wires first.
- Cut original wires from factory interior harness (ONE AT A TIME) and reattach to wire from same position on connector block of repair harness.
- Continue splicing wires (stagger splices) until all wires from interior harness are connected to repair harness.
With all wires from interior harness spliced to the repair harness:
- Fold and tape any unused wires (on repair harness) back to harness.
- Reinstall contact housing cover and re-tape wire harness.
- Route repair wire harness through plastic harness guide.
- Install repair wire harness connector to the B-pillar.
- Lubricate contact housing terminals with anti-corrosion grease, Part No: G 0521 74.A1
Reconnect door wire harness connector to B-pillar connector.
- Reconnect battery ground strap.
- Test all door electrical functions.
- Reinstall lower B-pillar trim.
- Reinstall upper B-pillar trim.
- Connect the VAS 5051 diagnostic tool.
- Check and erase any stored DTC's.
- Program radio station presets if necessary.
- Check vehicle equipment (radio code, clock, electrical windows) as per Repair Manual and/or Owner's Manual.