Replacing Wire Harness For PASM

Replacing Wire Harness For PASM

Tools

Preliminary work

Preliminary work for wire harness for front PASM
1. Disconnect battery.
2. Remove plenum panel cover.

Preliminary work for wire harness for rear PASM
1. Disconnect battery.
2. Remove subwoofer for BOSE sound system (I No. 680).
3. Lift up and remove carpet lining behind the backrest.

Preliminary work for wire harness for rear PASM
1. Disconnect battery.
2. Move convertible top to service position.
3. Removing cover over the motor
3.1. To loosen the carpet, pull out the plastic clips with the removal tool, universal NR.21 and remove the carpet.

Removing wire harness for PASM

Removing wire harness for front PASM

1. Unlock PASM plug connection -Arrow a- and disconnect it.

NOTE: When cutting the PASM wire harness, make sure there is enough length of cable left to join to the new lines.

2. Cut wire harness for PASM at -b- and remove it.
3. Cut through the fabric tape at -c- and expose the remaining PASM wires.

Removing wire harness for rear PASM

1. Unlock PASM plug connection -Arrow a- and disconnect it.

NOTE:
- 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.

2. Crimp the lines at -a-.
2.1. Cut off lines in different lengths (due to the shrink-fit connections).
2.2. Slide shrink-fit hoses onto the lines.
2.3. Strip 10 mm of insulation off the lines.
2.4. Crimp the lines using crimping sleeves and the manual crimping pliers from the repair kit for wire harnesses NR.155-1.
2.5. 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 wire harnesses) so that they are watertight.
2.6. Wrap commercially available PVC tape all around the area of the connection points.

3. Secure the repaired area -a- to the main wire harness with tie-wraps.

Installing wire harness for rear PASM

NOTE:
- 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 wire harnesses NR.155-1.
- Crimping samples are to be prepared before beginning work.

1. Press the PASM plug connection together until it clicks into place.

NOTE:
- 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.

2. Crimp the lines at -a-.
2.1. Cut off lines in different lengths (due to the shrink-fit connections).
2.2. Slide shrink-fit hoses onto the lines.
2.3. Strip 10 mm of insulation off the lines.
2.4. Crimp the lines using crimping sleeves and the manual crimping pliers from the repair kit for wire harnesses NR.155-1.
2.5. 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 wire harnesses) so that they are watertight.
2.6. Wrap commercially available PVC tape all around the area of the connection points.

3. Secure the repaired area -a- to the main wire harness with tie-wraps.

Installing wire harness for rear PASM

NOTE:
- 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 wire harnesses NR.155-1.
- Crimping samples are to be prepared before beginning work.

1. Press the PASM plug connection together until it clicks into place.

NOTE:
- 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.

2. Crimp the lines at -a-.
2.1. Cut off lines in different lengths (due to the shrink-fit connections).
2.2. Slide shrink-fit hoses onto the lines.
2.3. Strip 10 mm of insulation off the lines.
2.4. Crimp the lines using crimping sleeves and the manual crimping pliers from the repair kit for wire harnesses NR.155-1.
2.5. 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 wire harnesses) so that they are watertight.
2.6. Wrap commercially available PVC tape all around the area of the connection points.

3. Secure the repaired area -a- to the main wire harness with tie-wraps.

Subsequent work

Subsequent work for wire harness for front PASM
1. Install plenum panel cover.
2. Carry out work instructions after disconnecting the battery.

Subsequent work for wire harness for rear PASM
1. Fit carpet lining behind the backrest.
2. Install subwoofer for BOSE sound system (I No. 680).
3. Carry out work instructions after disconnecting the battery.

Subsequent work for wire harness for rear PASM
1. Fit carpet over the motor.
1.1. Lay the carpet over the motor and secure with the plastic clips.

2. Move convertible top from service position.
3. Carry out work instructions after disconnecting the battery.