Joining the Cables

Joining the cables
Special tools: 951 2785 , 951 2777.


NOTE: As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.


CAUTION: For SRS cables, see Cable harness SRS system, repair.


Preparatory work







Disconnect the battery negative lead.


NOTE: If several cables are to be spliced at the same point, spread out the splice points, as illustrated.







Expose the cable harness.

Splicing a joint using an insulated moisture proof butt connector
Preparations












Select a suitable butt connector according to the cable area. See the table.







Strip both ends of the cable according to the table above. Use stripping tool 951 2620.

Splicing cables of different areas







If the cable areas are so different that they will not fit in the same butt connector. Select a butt connector suitable for the larger cable. Strip the larger cable according to the table.

Strip the thinner cable to double length and fold the stripped length double.

Junction point







Several cables can be joined together in one splice point.

Crimping the sleeve







Insert the crimping sleeve in the press tool 951 2785. Choose the socket by color marking. Squeeze the crimping tool a little to secure the crimping sleeve in the tool.

Insert the cable as far into the crimping sleeve as it will go. Ensure that the cable insulation does not get into the crimping area and that the stripped cable does not protrude from the sleeve.

Press the plier handles as far as they will go to ensure a proper joint. The pliers release automatically.







Check by hand that the crimping sleeve is secure.

Heat the heat-shrink tubing







Place a suitable protection behind to shield the surrounding components from heat.
Heat the sleeve using hot air gun 951 2777 and a suitable nozzle. It is important that the heat-shrink tubing is shrunk around the cable. It should be possible to see that some adhesive has squeezed out around the cable.

Finishing work







Reinstall the cable harness. If necessary use a crimping sleeve and tie straps.
Reconnect the battery negative lead.
Test the function.