Impact Sensor: Service and Repair
Repair wire with two pressure-contact sleeves (Part No 82988-24010) has been prepared for exclusive use in repairing connector damage etc. caused by frontal collision of the vehicle.
When repairing the front airbag sensor connector on the wire harness side, always use the special repair wire.
NOTICE: Do not replace the connector housing or terminal only.
REPLACEMENT OF AIRBAG REPAIR WIRE
CAUTION: Work must be started after approx. 30 seconds or longer from the time the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery.
1. DISCONNECT WIRE HARNESS AT VEHICLE SIDE
(a) Remove the cover at the rear of the connector housing and expose the wire harness.
(b) Cut the wire harness behind the connector housing.
HINT: The operation is performed more easily if the wire harness is left as long as possible.
2. CONNECT FRONT AIRBAG SENSOR WIRE HARNESS AT VEHICLE SIDE AND REPAIR WIRE
(a) Start stripping at least 8 mm (0.31 in) to 11 mm (0.43 in) away from the end of the existing harness at vehicle side and also from the end of the repair wire.
NOTICE: Take care not to damage the wire when stripping the wire harness lead. After finishing the operation, visually inspect the wire. If there is any damage, perform the operation again.
(b) Overlap the two stripped wire ends inside of the pressure contact sleeve as illustrated above.
HINT: The blue pressure-contact sleeve (Part No. 82999-1 2020) is available as a solitary spare part.
HINT: You might find it easier if you use a miniature screwdriver as a guide as you insert wires into the sleeve.
(c) The crimping tool (AMP Part No. 169060) has color marks on it. Place the sleeve in the correct section of the tool according to the color of the sleeve itself.
HINT: As the crimping tool, AMP Part No. 169060 is convenient to use.
(d) With the center of the sleeve correctly placed between the crimping jaws, squeeze the crimping tool until either end comes into contact at the section marked "CLOSE HERE".
HINT: Check to see that the sleeve and wires are still in the correct position before closing the crimping tool ends with steady pressure.
(e) Pull the joined wires to either end. Make sure that they are joined firmly by the sleeve.
NOTICE: If the joined wires come loose the splice is defective, so replace the sleeve and repeat the procedure.
(f) Crimp both ends of the sleeve with the crimping tool at the "INS" position.
3. PROTECT JOINED SECTION
Wrap silicon tape around the joins to protect them from water.
HINT:
^ Before starting the operation, thoroughly wipe dirt and grease off the sections to be joined.
^ If the adhesive surfaces of two tapes come in contact they will stick together and will not come apart, so do not remove the backing film except when using the tape.
^ Do not let oil and dust, etc. get on the tape surface.
(a) Ready about 100 mm (3.94 in) of silicon tape (Part No. 08231-00045) and peel off the film.
(b) Stretch the silicon tape until its width is reduced by half.
(c) About 10 mm (0.39 in.) from the end of the pressure- contact sleeve, wrap the silicon tape around the sleeve three or more times while stretching the tape.
(d) Wrap the remaining part of sleeve with half of the tape overlapping at each turn.
(e) Firmly wrap the tape two times or more about 10 mm (0.39 in.) from the other end of the pressure-contact sleeve, then wrap the tape back towards the start again and firmly finish winding the tape around the center of the sleeve.
(f) Fix the corrugated tube to the wire using silicon tape.
(g) After applying the silicon tape, apply vinyl tape on the corrugated tube of repair wire side over to the corrugated tube of vehicle wire harness side.