Procedures

Cable harness SRS system, repair

Special tools: 951 2785 Crimping tool 951 2785 Crimping Tool , 951 2620 Stripping tool 951 2620 Stripping Tool , 951 2777 Hot-air gun 951 2777 Hot Air Gun
Materials: SRS system repair kit for the selected car.

Note! 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! As the SRS system is a safety system, it is extremely important that these instructions are carefully followed when carrying out repairs in the cable harness.

Caution! Ensure that the new pin has the same type of surface treatment as the old.

Only special tools and materials from the SRS system repair kit for the selected car must be used. Choose a repair location where there is plenty of room to guarantee that work is of the highest quality.
The cables should always be connected colour to colour. If the repair terminal colours do not correspond with the vehicle, check with the wiring diagram for the vehicle in question. In the cases where the repair terminals have a completely orange cable then this is always fitted to terminal No. 1. In the cases where the repair terminals have a blue and a brown cable, then blue is No. 1 and brown is No. 2.

Warning! Do not carry out any work on the SRS cable until the connector has been disconnected from the relevant airbag or seat belt tensioner. There is otherwise a risk of static electricity deploying the component.

Before work in the cable harness
Always disconnect the battery. See Battery, disconnecting Battery Disconnecting
Disconnect the relevant ignition cable. See Igniter wire connector Igniter Wire Connector

Cut and strip the cables




Release the cable from the cable harness so that you have plenty of room in which to work.

Note! The maximum permitted twinned length after splicing is 100mm. This is to prevent interference problems.

Cut the cables so that there is approximately 40 mm between the splices (centre to centre) (A).




Strip the insulation on the 4 cable ends by 5.0 mm. Use pliers 951 2620 Stripping tool 951 2620 Stripping Tool.
Twin the cable cores on the stripped ends of the cables.

Caution! Ensure that all the cores are twinned.

Crimping the sleeve




Install a crimp sleeve from the repair kit in the press tool:951 2785 Crimping tool 951 2785 Crimping Tool
Squeeze the crimping tool a little to secure the crimping sleeve in the tool.
Insert the cable as far into the crimp sleeve as it will go.
Ensure that the cable insulation does not get into the crimping area or that stripped cable does not extend outside the sleeve.
Press the pliers' 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.
Prepare the remaining cable ends in the same way.










Heat the heat-shrink tubing




Hold a putty knife or other suitable protection behind the heat-shrink tubing to shield the surrounding components from heat.
Heat the sleeve using the hot air gun 951 2777 Hot-air gun 951 2777 Hot Air Gun and a suitable nozzle. It is very important that the heat-shrink tubing is thoroughly shrunk around the cable. It should be possible to see some adhesive that has squeezed out around the cable.






Reinstalling and checking
Secure the new SRS cable next to the old cable using a tie strap or similar. Reinstall the connectors.
Reconnect the battery. See Battery, disconnecting Battery Disconnecting
Turn the ignition to position 2.
Check the SRS system to ensure that the warning lamp comes on and stays on while the SRS system performs a self-test. The lamp must go out after a few seconds. If not, perform fault-tracing according to VIDA vehicle communication.
If everything is working, reinstall other components.
Test drive the vehicle.