Antilock Brakes / Traction Control Systems: Service and Repair

Replacing Wire Harness For Anti-lock Brake System (ABS)

Tools







Technical values







Preliminary work

Preliminary work on front ABS wire harness
1. Disconnect battery.
2. Remove front wheel housing liner (rear section).
3. Remove plenum panel cover.

Preliminary work on rear ABS wire harness
1. Disconnect battery.
2. Remove wheel.
3. Remove rear backrest.
4. Remove the rear side trim panel.
5. Remove trim panel for seat well.

Removing wire harness for anti-lock brake system (ABS)

Removing front ABS wire harness












1. Release the cable retainer -arrow A- and pull off the two connectors -arrow B-.
2. Unscrew the fastening screw and remove the connector socket -arrow C-.







3. Remove the ABS wire harness from the brackets -arrows A-.
4. Open the clips -arrows B- and remove the ABS wire harness -arrow C-.
5. Remove the fabric tape -D-.

INFORMATION: When cutting the ABS wire harness, make sure that there is enough line length left to join to the new lines.

6. Cut off the ABS wire harness around -E- and remove it.







7. Cut through the fabric tape in the plenum panel, in the area around -a-, and expose the remaining ABS lines.

Removing rear ABS wire harness












1. Release the cable retainer -arrow A- and pull off the two connectors -arrow B-.
2. Unscrew the fastening nut and remove the connector socket -arrow C-.







3. Remove the ABS wire harness from the brackets -arrows-.

INFORMATION: When cutting the ABS wire harness, make sure that there is enough line length left to join to the new lines.







4. Cut off the ABS wire harness around -a- and press inward with the rubber sleeve -b- -arrow-.

INFORMATION: Only for vehicles with TPM.







5. Cut through the rubber sleeve at the side of the HBA line -a- and remove the HBA line -arrow-.

Installing wire harness for anti-lock brake system (ABS)

Installing front ABS wire harness







1. Place socket in installation position -arrow A- and screw on the fastening screw. - Tightening torque: 10 Nm (7.5 ftlb.)
2. Plug in the two connectors -arrow B-.
3. Fold back the cable retainer -arrow C- until it engages correctly at the connectors.







4. Press the ABS wire harness into the supports by pressing on the rubber sleeves -arrows A-.
5. Secure line for headlight levelling system to the ABS wire harness using fabric tape -B-.
6. Place ABS wire harness in installation position -arrows C- and close clip -arrows D-.







7. Push through ABS wire harness to plenum panel -arrow-.

INFORMATION:
- Select a place for the joint where there is enough space to join all the lines present.
- Do not cut the lines too short in case they have to be laid in a different position if there is insufficient space in the area of the joint.
- The electric lines are located in the plenum panel and are thus exposed to the highest demands.
- The greatest care must be used in the individual work steps for stripping insulation from, crimping, and shrinking/insulating the electric lines.
- The procedure for stripping insulation from, crimping, and shrinking/insulating the electric lines must be complied with and observed. The procedures are described in detail in the repair kit for harnesses NR.155-1.
- Crimping samples are to be prepared before beginning work.

8. Crimp lines in area around -b-.
8.1. Cut off lines in different lengths (due to the shrink-fit connections).
8.2. Slide shrink-fit hoses onto the lines.
8.3. Strip 10 mm of insulation off the wires.
8.4. Crimp lines using crimping sleeves and the hand crimping pliers from the repair kit for harnesses NR.155-1.
8.5. Slide the shrink-fit hoses over the crimp connections and carefully shrink them using the hot-air blower with special nozzle (recommended accessories for the repair kit for harnesses) so that they are watertight.
8.6. Wrap commercially available PVC tape all around the area of the connection points.

9. Secure the repaired area to the neighbouring wire harnesses using tie-wraps -c-.

Installing rear ABS wire harness







1. Place socket in installation position -arrow A- and screw on the fastening nut. - Tightening torque: 10 Nm (7.5 ftlb.)
2. Plug in the two connectors -arrow B-.
3. Fold back the cable retainer -arrow C- until it engages correctly at the connectors.







4. Press the ABS wire harness into the supports by pressing on the rubber sleeves -arrows-.







5. Push the ABS wire harness inward -arrow- .

INFORMATION: Only for vehicles with TPM.







6. Cut through the rubber sleeve -a- and insert the HBA line -arrow A-. Stick the rubber sleeve together at the cut edge -a- using a commercially available PUR adhesive and seal. Press the rubber seal into the opening -arrow B-.

INFORMATION:
- Select a place for the joint where there is enough space to join all the lines present.
- Do not cut the lines too short in case they have to be laid in a different position if there is insufficient space in the area of the joint.
- The greatest care must be used in the individual work steps for stripping insulation from, crimping, and shrinking/insulating the electric lines.
- The procedure for stripping insulation from, crimping, and shrinking/insulating the electric lines must be complied with and observed. The procedures are described in detail in the repair kit for harnesses NR.155-1.
- Crimping samples are to be prepared before beginning work.

7. Crimp lines in area around -b-.
7.1. Cut off lines in different lengths (due to the shrink-fit connections).
7.2. Slide shrink-fit hoses onto the lines.
7.3. Strip 10 mm of insulation off the wires.
7.4. Crimp lines using crimping sleeves and the hand crimping pliers from the repair kit for harnesses NR.155-1.
7.5. Slide the shrink-fit hoses over the crimp connections and carefully shrink them using the hot-air blower with special nozzle (recommended accessories for the repair kit for harnesses) so that they are watertight.







7.6. Wrap commercially available PVC tape all around the area of the connection points.

Subsequent work

Subsequent work on front ABS wire harness
1. Install plenum panel cover.
2. Install front wheel housing liner (rear section).
3. Carry out work instruction after disconnecting the battery.

Subsequent work on rear ABS wire harness
1. Install trim panel for seat well.
2. Install rear side trim panel.
3. Remove rear backrest.
4. Install wheel.
5. Carry out work instruction after disconnecting the battery.