Wiring
Contents
1. Operating instructions The heat gun is used in two ways It can either be held in the hand and used directly Or it can be set down on its supports O on a clean and tidy bench The latter has the advantage of leaving the user with both hands free Programs Always work with the FREE program shown on the screen J at T If it is not shown perform the following operation press menu selection button K once program field T on the display screen J flashes select the free program using the L or N buttons press the menu selection button K once so that field T on the display screen J stops flashing 88A 12 WIRING Wiring repair kit Use e Temperature and air flow settings To change the program settings the FREE program is recommended carry out the following operation press the menu selection button K twice the temperature field U on the display screen J flashes adjust the temperature using the L or N buttons press the menu selection button K once the air flow field V on the display screen J flashes adjust the air flow using the L or N buttons press the menu selection button K once so that the fields on the display screen J stop flashing Note When using the heat gun on crimping or self solder sleeves the air flow is always on the maximum setting only the temperature varies 882. IMPORTANT The cross section of replacement wire must not be less than the original cross section of wire IMPORTANT Use a 0 5 mm wire to repair a 0 35 mm wire Slide the sleeve over the stripped section The ring of solder should end up in the centre of the stripped and twisted wires A The stripped and twisted IMPORTANT section of the wires must be located between the The temperature class of the replacement wire 2 sealing rings B must be equal to or greater than class T3 For the repair use the wires recommended by the Parts Department checking that they are suitable for your requirements Strip the ends by the lengths indicated in relation to the sleeve chosen using the stripping pliers see 88A Wiring Wiring repair kit Use Protect sensitive areas close to the wiring with the heat shield 88A 19 WIRING Wiring Repair IMPORTANT When the sleeve is positioned check that all the copper strands remain flat and subsequently are not at risk of perforating the sleeve Start the operation to join the wires again if necessary NOTE The sealing rings must be clearly located on the insulated section of the wires B and not on the copper or where the copper and the insulated section meet Start the operation to join the wires again if necessary Once the wires are joined start the heating operation Heating the self solder sleeve Switch on the heat gun fitted with
3. Check that the length of replacement wire is the same as that removed from the harness plus 30 mm for the wire joints After the operation check that the wire is not too taut or too long when the seat is furthest forward or back Protect the wires so that they are not damaged and this new branch is correctly maintained Hanging loops are not allowed regardless of the wires involved in the repair Carry out the specific airbag and pretensioner line repair checks See Airbag line repair check and Final check in this section Note Check that the harness is correctly repositioned after the operation and that it does not obstruct the seat adjusting mechanisms 3 Pyrotechnic component connectors These are airbag and pretensioner trigger connectors Identify the connector concerned on the vehicle Repair is possible if it is a SQUIB connector 88C Find the colour of the connector Blue green or orange Find the shape of the connector Straight or angled Select the same connector colour and shape from the airbag connectors kit see under DIALOGYS Example of an angled SQUIB connector Apply the specific procedure for repairing multiplex lines see 88B Multiplex Multiplex network Repair except the section on locating the fault to replace the connector Carry out the specific airbag and pretensioner line repair checks See Airbag line repair check and Final check in this section 88C 2 AIR
4. Disconnect the battery see the MR corresponding to the vehicle 80A Battery Battery Removal Refitting Remove the components necessary to enable access to the wiring Detach the section of wire to be repaired from the main wiring Cut the wires at B and C 50 mm on each side of the damage Strip each end of the wires by 10 mm F at each side From the coil of twisted wires 0 5 mm specific number of turns to be used to repair the multiplexing take a length of wire the same as that removed from the harness plus 30 mm for the wire joints see 88A Wiring Wiring repair kit Description 88B 2 MULTIPLEXING Multiplex network Repair 88 B To join the wires working wire by wire Refer to the precautions for use relating to self solder slip the self solder sleeve onto the wire sleeves see 88A Wiring Wiring Repair twist the end of the wires together IMPORTANT Do not try to heat the sheath too quickly use a backwards and forwards motion to ensure that it does not burn Do not direct the flow of hot air onto the insulation of the wires so as not to burn it Note For the soldering to be complete and for the sheath to contract the heating operation should last about 30s 10 Spend the majority of the recommended time on the ring of solder and the rest of the time on the ends of the sleeve The recommended time is given as a guide It can be reduced or increased depending on how
5. does not authorise operations directly on the connectors and electrical contacts Only wiring connector kits allow the replacement of a connector These kits can have associated procedures Note To check whether there is a wiring connector kit consult DIALOGYS These kits are generally linked to specific wiring or function diagrams Note If the fault is located at the electrical contact in the connector and if it is linked to a corrosion or heating fault replace the wiring or fit the wiring connector kit Also check the connector complement Note In all cases pay particular attention to supply and earth lines and their tightening refer to the tightening torques in the MRs concerned After having carried out the checks outlined in the Summary flowchart of the investigation procedure if the repair is authorised and it does not require a specific procedure carry out the generic procedure see 88A Wiring Wiring Repair Note If you have been referred to this note by an MR Technical Note or removal refitting procedure apply the repair procedure adapted to the case in question Either the generic repair procedure see 88A Wiring Wiring Repair or a specific procedure listed in the specific procedures reference table in this section WIRING Wiring Precautions for repair 88A 2 Specific procedures reference table e Guidelines for reading the tables below If not otherwise stated conside
6. the concentrator nozzle after familiarising yourself with the precautions for use see 88A Wiring Wiring repair kit Use Adjust the temperature and the air flow to the values indicated see 88A Wiring Wiring repair kit Use Check that the sensitive areas close to the sleeve and the other electrical wires are not at risk of damage Heat the sleeve starting at the centre concentrating the heat on the ring of solder and the stripped section of the wires When the copper and the ring of solder become hot enough the ring of solder melts and runs in between the copper strands C When the solder has completely melted move the nozzle to the ends of the sleeve to finish shrinking the sheath The sealing rings of the sleeve tighten around the insulation of the wires D 88A 20 Note Spend the majority of the recommended time on the ring of solder and the rest of the time on the ends of the sleeve The heating operation takes 30 s 10 This time is a guide only It can be reduced or increased depending on how efficient the heating is IMPORTANT Do not try to heat the sheath too quickly use a backwards and forwards motion to ensure it does not burn Do not direct the flow of hot air onto the insulation of the wires so as not to burn it WIRING Wiring Repair S8A IMPORTANT When joining 2 wires to 1 wire first connect the 2 wires from the same end in the following way Wa
7. the vehicle concerned Apply the recommendations from the generic repair procedure concerning the fitting and protection see 88A Wiring Wiring Check 6 Final check After any operation on a wiring harness check that there are no faults with the diagnostic tools Clip EasyClip etc Refer to the fault finding procedure for the airbag and pretensioner function concerned If a fault is present pass on the vehicle fault finding to a qualified operator automotive electrician technician agent or cotech level 2 minimum 88C 3
8. 1 Result of the fault finding procedure Note During repair check that you have the most recently updated version of the Technical Note A preliminary fault finding procedure has enabled a wiring fault to be identified Follow the investigation procedure below Disconnect the battery see the MR corresponding to the vehicle 80A Battery Battery Removal Refitting Remove the components necessary to access the area to be worked on The operation area must allow the pliers and the heat gun to be used without blocking visibility IMPORTANT If the damaged section is not sufficiently accessible remove the wiring concerned and repair on the bench When the damaged section is sufficiently accessible detach the wires to be repaired from the main wiring IMPORTANT Check if there is a sensitive line These cases are listed in the specific procedures reference table in this section If there is a sensitive line replace the defective wiring or apply the specific procedure if one exists These procedures are indicated in the specific procedures reference table in this section Check that the fault is located more than 10 cm from the connector 88A 1 NOTE If the damaged section is located less than 10 cm from the connector replace the defective wiring unless a wiring connector kit connector with wires exists In this case use the kit to replace the damaged section and the connector This note
9. A 13 88A WIRING Wiring repair kit Use 88A Special modes COOL PAUSE After use and before setting switch A to OFF 0 cool the gun Similarly during brief pauses or for lower power consumption switch the gun to PAUSE mode by carrying out the following operation Before switching off the heat gun press the STANDBY button M once the program field T on the display screen J shows COOL wait until the temperature goes down to 150 C and set switch A to OFF 0 To switch to economy mode press the STANDBY button M once the program field T on the display screen J shows COOL press the STANDBY button M once the program field T on the display screen J shows WAIT the gun is in economy mode press the STANDBY button M once to recover the previous settings and start heating again 88A 14 WIRING Wiring Repair Note This relates to the generic repair procedure 1 Choosing the sleeve The are two possible techniques available self solder sleeves crimp sleeves For each technique there are 3 sizes of sleeve The choice of sleeve depends on the following criteria Type of operation Note This is stage 1 when using the label If wire to wire 1 to 1 use crimp sleeves or self solder sleeves 88A If 2 wires and 1 wire 2 to 1 only use crimp sleeves In this case the seal can no longer be guaranteed Do n
10. BAGS AND PRETENSIONERS Airbag and pretensioner wiring Repair 4 Airbag and Pretensioner harness damage IMPORTANT No operation is authorised unless it is possible to check the repair using the diagnostic tool Where the repair can be checked with the diagnostic tool if it is a case of twisted wires with a cross section less than or equal to 0 5 mm apply the multiplex lines specific repair procedure see 88B Multiplex Multiplex network Repair except the section on locating the fault for the repair of the lines if it does not concern twisted wires apply the generic procedure for repairing the harness see 88A Wiring Wiring Check Carry out the specific airbag and pretensioner line repair checks See Airbag line repair check and Final check in this section 88C 5 Airbag lines repair check Confirm the airbag line repair to ensure that the repair is correct Check the quality of the operation by measuring the impedance produced by the computer using the diagnostic tool Unlock the airbag computer using the diagnostic tools The warning light should no longer be on Note During the check with the diagnostic tool move the lines forwards and backwards slightly The resistance measurement should remain stable if variations in resistance are noticed start the repair operation again for the defective line Refer to the airbag and pretensioner function fault finding procedure for
11. RENAULT Technical Note 6015A All types Sub sections concerned 88A 88B 88C ELECTRICAL WIRING REPAIR This note cancels and replaces Technical Notes 8074 and 8075 77 11 332 302 September 2005 EDITION ANGLAISE The repair procedures given by the Manufacturer in this document are based on the All rights reserved by RENAULT s a s technical specifications current when it was prepared Copying or translating in part or in full of this document or use of the service part The procedures may be modified as a result of changes introduced by the reference numbering system is prohibited without the prior written authority of manufacturer in the production of the various component units and accessories from RENAULT s a s which his vehicles are constructed Renault s a s 2005 ELECTRICAL WIRING REPAIR Contents Page WIRING Wiring Precautions for repair 88A 1 Wiring repair kit General information 88A 5 Wiring repair kit Description 88A 6 Wiring repair kit Use 88A 9 Wiring Repair 88A 14 Wiring Check 88A 23 Connector Repair 88A 26 MULTIPLEXING Multiplex network Repair 88B 1 AIRBAGS AND PRETENSIONERS Airbag and pretensioner wiring Repair 88C 1 WIRING Wiring Precautions for repair 88A IMPORTANT This note authorises the repair of electrical wiring in very specific cases only and under certain conditions Check that the repair in question is authorised and that the repair conditions are respected
12. ain cases wiring connector kits can have different colours to those of the wiring to be repaired e cut the connector wires to be replaced to a length greater than 100 mm and stagger the cuts e shorten the wiring connector kit wires so as to obtain wires the same lengths as those cut from the wiring to be repaired For self solder sleeves add 30 mm for the wire joints apply the generic repair procedure for the joint see 88A Wiring Wiring Repair 3 Checking and fitting the repair with wiring connector kits Carry out the generic repair procedure check see 88A Wiring Wiring Check or that of the specific procedures if it is a specific case see 88A Wiring Wiring Precautions for repair Apply the recommendations from the generic repair procedure concerning the fitting and fuses see 88A Wiring Wiring Check 4 Final check After any operation on a wiring harness check that there are no faults with the diagnostic tools Clip EasyClip etc Refer to the corresponding fault finding procedure If a fault is present pass on the vehicle fault finding to a qualified operator automotive electrician technician agent or cotech level 2 minimum MULTIPLEXING Multiplex network Repair 88 B IMPORTANT 2 Necessary equipment This procedure relates tothe repair ot the For repairing the multiplex network use the components of the wiring repair kit see 88A Wiring Wiring repair kit Descript
13. cian agent or cotech level 2 minimum 88A 26 WIRING 88A Connector Repair IMPORTANT Apply this procedure when there is a connector wiring kit Unless the connector wiring kit is linked to one of the sensitive lines listed in the specific procedures reference table see 88A Wiring Wiring Precautions for repair In this case apply the specific procedure for the sensitive line concerned 1 Wiring Connector kit A wiring connector kit enables a repair to be carried out when the connector is defective or when the fault is located less than 10 cm from the connector A wiring connector kit is generally made up of at least 1 connector crimped wires with corresponding contacts sealing components if the connector is sealed e the self solder or crimp sleeves necessary for the repair other components specific to the function concerned e g fuses 2 Using a wiring connector kit Except in the specific outlined cases use the wiring connector kits as follows check that the kit is complete check that the connnector configuration position of wires in the cells of the connector corresponds to your needs e check that the wire cross sections of the wiring connector kit are equal to or larger than the cross section of wires to be repaired mark the wires to ensure that the tracks are not reversed 88A 27 IMPORTANT The colour of the wires cannot serve as a marker In cert
14. ck IMPORTANT The various struck through cases are strictly forbidden 88B 4 hii2i The two wires added are of a different length 5 Final check After any operation on a wiring harness check that there are no faults with the diagnostic tools Clip EasyClip etc Refer to the corresponding fault finding procedure If a fault is present pass on the vehicle fault finding to a qualified operator automotive electrician technician agent or cotech level 2 minimum AIRBAGS AND PRETENSIONERS 88C Airbag and pretensioner wiring Repair IMPORTANT This procedure relates to the repair of airbag and pretensioner wiring only Note Apply all the precautions and recommendations shown in the MRs IMPORTANT All work on airbag and pretensioner systems must be carried out by qualified trained personnel IMPORTANT The pyrotechnic systems pretensioners or airbags must not be handled near to a heat source or flame there is a risk that they may be triggered IMPORTANT Before removing an electronic control unit ECU or before any operation on the safety systems or around them the airbag computer must be locked using the diagnostic tool When this function is activated all the trigger lines are inhibited and the airbag warning light on the instrument panel is lit continuously IMPORTANT Before any operation on a pyrotechnic component connection connector or wiring found defective during fault finding discon
15. d advice in the user s manual into account e Description of the heat gun 1 On 1 off 0 switch J Display screen K SELECT MENU button L button for setting parameters M STANDBY button pause cooling N button for setting parameters O Supports for resting the tool on a bench P Tool air inlet Q Tool air outlet 88A 11 88A e Accessories R Concentrator nozzle S Heat shield nozzle Note The concentrator nozzle R is recommended when using the heat gun on the crimping or self solder sleeves in the kit NOTE The heat shield nozzle S can be used for contracting single heat shrinkable sheaths Do not use it for contracting the crimping or self solder sleeves in the kit e General information on the setting parameters When contracting the sleeves in the kit use the FREE program and change the settings as recommended A memory function recalls the program and settings from the last time the gun was used WIRING Wiring repair kit Use 88A Switching on the gun Connect the appliance to the mains electricity supply 230 Vac 50 Hz or 60 Hz respecting all precautions Push the switch I on 1 The appliance will switch on at the programs and settings most recently used IMPORTANT The gun starts heating immediately IMPORTANT Before putting the gun away in its case or anywhere else leave it to cool down to ambient temperature
16. d crimp sleeve The insulation of the wires is within the sleeve Self solder sleeves The sealing rings must be clearly located on the insulated section of the wires Self solder sleeves The solder has completely melted e Crimp sleeves The adhesive of the crimp sleeves forms a barrier at the ends of the sleeves The sleeve has completely contracted around the insulation of the wires The sleeve is not cut slit discoloured or pierced by a copper strand The insulation of the wires does not show any sign of damage caused by overheating The wiring and the area surrounding it have not been damaged by the heating operation Result of a correctly applied self solder sleeve 88A 24 WIRING Wiring Check 88A The protruding strands of the wire have pierced the IMPORTANT self solder sleeve at K during contraction The various struck through cases are strictly forbidden The self solder sleeve has not been correctly shrunk At 1 the sealing ring has not contracted around the insulation of the wire The crimp sleeve has not been correctly shrunk At L the adhesive does not form a barrier at the end of the sleeve The sealing ring of the self solder sleeve is directly on the copper of the wire at J 113749 The adhesive of the crimp sleeve is directly on the copper of the wire at M 88A 25 WIRING Wiring Check The sleeve and the insulation of the wi
17. d from the single wire side 2 for red and blue crimp sleeves and 8 mm for the yellow sleeve If the two wires side 1 have the same cross section strip 10 mm from them for red and blue crimp sleeves and 11 mm for the yellow sleeve If the 2 wires side 1 have different cross sections then For red and blue crimp sleeves strip 10 mm from the smaller cross section and 7 mm from the larger cross section For the yellow sleeve strip 11 mm from the smaller cross section and 8 mm from the larger cross section NOTE If no sleeve corresponds to the case in question the operator cannot repair the wiring Replace the wiring harness 88A 17 WIRING 8 8 A Wiring Repair Settings table taken from the label Cow a f e a e O e 0 52s AtBs 1 57 1 52 lt A Bs2 54 37s A B lt 6 2 2 2 2 Wire cross eechane 0 32s A C lt 0 8 0 82s A Cs 2 22s A Cs 4 8 0 524 C21 52 81524 Gao etl 8 32 C 6 A a 3 A A o AC A C 7 A C 2 A C mamaaa o a 10 95 oo ow ee wo cs OO o vast ame eelo rre TATA AASS shame basme O E 5 15 ooo 7 7 amo E Mama O 58 ooo a7 ao nr ow arsenate fee 15 05 oo O e ow ede tian fame fos foo BO v 0 lO os as S Ey a ia cE A B C on A B C on A B C cae i eee 3 ae M 1x0 5 mm 5 2 1x1 5 mm 1x1 mm 1x0 5 mm 3 gt 1x2 mm 10 7 7 300 1x1 5 mm 1x0 5 mm 2 A 1x3 mm 11 8 8 320 1x3 mm In the case of a 1 to 1 type
18. eck that the sensitive areas close to the sleeve and the other electrical wires are not at risk of damage Heat the sleeve starting at the centre When the sheath starts to contract move the nozzle to one of the ends The sheath continues to contract and produces a glue When the end of the sleeve has completely contracted and the glue has correctly covered the opening of the sleeve repeat the operation on the other end to obtain the result shown at H 113690 88A Note Spend the majority of the recommended time on the metal barrel and the rest of the time on the ends of the sleeve The heating operation takes 30 s 10 This time is a guide only It can be reduced or increased depending on how efficient the heating is IMPORTANT Do not try to heat the sheath too quickly use a backwards and forwards motion to ensure it does not burn Do not direct the flow of hot air onto the insulation of the wires so as not to burn it IMPORTANT Wait for the sleeve to cool before manipulating it to ensure that the sealing properties of the sleeve are not affected minimum waiting period 1 minute Do not bend the sleeve even when cool so as to not damage the sealing properties of the sleeve When the heating operations have finished move on to the checking operation see 88A Wiring Wiring Check 88A 23 WIRING Wiring Check 88A 1 Visual checks Result of a correctly applie
19. efficient the IMPORTANT heating is The colour of the wires CAN H et CAN L must be respected when they are being joined NOTE Position the sleeve with its solder ring in the centre of Wait for the sleeve to cool before manipulating it the wire joint to maintain the quality of the solder minimum waiting period 1 minute Do not bend the sleeve even when cool so as to not damage the quality of the solder or the sealing properties of the sleeve Switch on the heat gun e Adjust the temperature of the gun to 340 C with the blower speed set to maximum see 88A Wiring Wiring repair kit Use Heat the sleeve so that the solder ring melts G onto the wires until the heat shrinkable sheath contracts 88B 3 MULTIPLEXING Multiplex network Repair 88 B No turns twists at H 4 Checking the multiplex line IMPORTANT After repairing the multiplex line always check the multiplex network using the diagnostic tool Note During the check with the diagnostic tool move the lines forwards and backwards slightly If a fault is recorded start the operation again for the defective line Refer to the fault finding procedure for the function concerned IMPORTANT After checking the multiplex line refit it in the main harness tape it up with adhesive tape Apply the recommendations from the generic repair procedure concerning the fitting and fuses see 88A Wiring Wiring Che
20. entifying the settings Note This is stage 3 when using the label After having found the case in question follow the corresponding line to find the setting parameters The settings correspond to the lengths to be stripped and the temperature of the heat gun The column corresponding to these parameters gives the recommended sleeve Note If several sleeves are possible for the same operation choose the one best suited for the number of wires to be repaired the wiring layout and the vehicle layout thickness of the harness available room etc As relates to the previous examples Example 1 2 possible sleeves Either the blue self solder sleeve Or the red crimp sleeve Example 2 Only the blue crimp sleeve is possible e Special cases If the case in question is not shown in the selection table apply the following rules to select a sleeve In all cases identify the cross section of each wire copper strands 88A 16 WIRING Wiring Repair e Case of a wire joint between 1 wire and 1 wire most common situation Conditions for self solder sleeves Add together the 2 wire cross sections copper strands If 0 3 mm lt section 1 section 2 lt 0 8 mm use the self solder sleeve with clear rings Strip 10 mm from each wire The temperature setting is 300 C 2 use the If 0 8 mm lt section 1 section 2 lt 2mm self solder sleeve with red rings Strip 12 mm from each
21. eve At F for crimping the red crimp sleeve At G for crimping the blue crimp sleeve At H for crimping the yellow crimp sleeve Before crimping a sleeve choose the sleeve appropriate to the cross section of the wire see 88A Wiring Wiring Repair strip the recommended length of wire 88A e Crimping operation Squeeze the handles fully together to unlock the pliers and open the jaws On the pliers find the crimping jaws which correspond to the sleeve being used Insert the wire s into one end of the sleeve Position the pliers jaws in the middle of the half of the metal shaft where the wire s are Squeeze the handles fully together to crimp the sleeve onto the wire s Crimping is complete once the pliers are opened again Check that the copper of the wire is correctly crimped and that the plastic part of the sleeve has not been cut Repeat the crimping operation on the other end of the sleeve Note If the wire is not correctly crimped cut the wire at the sleeve and start the operation again with a new sleeve 88A 10 WIRING Wiring repair kit Use 3 Heat gun IMPORTANT Before using the gun the user must familiarise themselves with the safety advice in the user s manual provided by the manufacturer e Introduction to the gun The heat gun is recommended for contracting heat shrinkable sleeves For other applications the user must take the precautions an
22. g and Pretensioner Wiring Repair Airbag computer connector see 88C Airbags and Pretensioners Airbag and Pretensioner Wiring Repair see 88C Airbags and Pretensioners Airbag and Pretensioner Wiring Repair Se a 88A 2 WIRING Wiring Precautions for repair 88A General cases Functions or components Wiring harness Number of damaged wires 10 or see 88A Wiring Wiring Repair fewer Number of damaged wires more Change the wiring than 10 Equipment and Change the wiring predispositions specific to commercial vehicles and conversions Connections or see 88A Wiring Connector Repair associated components Splice with 3 wires or more which Change the wiring needs sealing engine and underbody areas and damp areas of the doors and boot Wires outside the loom Sheathed wires Change the wiring Shielded wires Change the wiring Twisted wires if the wire cross sections are 0 5 mm2 see 88B Multiplex Multiplex network Repair Flat cable Change the wiring Wires with specific thermal Change the wiring protection Wires with copper cross section Change the wiring less than 0 35 mm Wires with copper cross section Change the wiring greater than 6 mm Wires damaged less than 10 cm see 88A Wiring Connector Repair from the connector Splices Splice with more than 3 wires Change the wiring 3 wire splice which does not need see 88A Wiring Wiring Repair sealing 88A 3 WIRING Wir
23. hree sizes of heat shrinkable crimp sleeve differentiated by the colour of their rings Red for a copper cross section between 0 5 and 1 5 mm Blue for a copper cross section between 1 5 and 2 5 mm Yellow for a copper cross section between 3 0 and 6 0 mm These are sealing sleeves The seal is formed by the inner wall which becomes adhesive when heated This is a coil of a twisted pair of wires 40 turns linear m Ensure these wires remain twisted These sleeves can be used to join one wire with The 2 wires have a 0 5 mm cross section and are of another wire 1 to 1 or two wires with another wire temperature class T3 It is possible to fit them in all 2 to 1 areas of the vehicle during repairs to twisted wires of the same cross section In the case where two wires are joined to one wire 2 to 1 the seal is no longer guaranteed Do not use when a Seal is required Heat shield The heat shield screen is a 250 mm by 250 mm square It is intended to protect the surrounding area from the flow of hot air from the heat gun 88A 8 WIRING Wiring repair kit Use Note This section is an abridged version of the instructions for use of the tools in the kit 1 Stripping pliers e Description of the stripping pliers A Wire cutter B Stop for adjusting the length to be stripped C Scale millimetre divisions D Pressure adjustment E Stripping jaws and c
24. ing Precautions for repair 88A 3 Summary flowchart of the investigation procedure defined in this section Identification of a fault on the wiring Disconnect the battery see the MR for the vehicle 80A Battery Battery Removal Refitting Access the area concerned NO Case of referral to Technical Note 6015A from an MR a Sufficient accessibility YES Remove the wiring YES Technical Note or a removal refitting procedure Fault on a sensitive NO line or equivalent see table no Caused by connector Is there a specific procedure see table YES YES Is there a specific kit DIALOGYS NO Is there a connector kit DIALOGYS YES Procedure attached to connector kit see table table Specific procedures reference table Fault more than 10 cm from the connector Generic repair procedure see 88A Wiring Wiring Repair Fault more than 10 cm from the connector YES Specific repair procedure see table Change the wiring 88A 4 WIRING Wiring repair kit General information 1 Purpose and applications Description of the content of the Wiring repair kit case as well as the procedure and the field of application The kit enables wiring which is damaged or has cut electrical wires to be repaired while retaining its operating characteristics It also allo
25. ion multiplex network alone twisted wires 1 Locating the fault Use the self solder sleeves with red rings A for making the joints Use the diagnostic tool clip to test the multiplex network see the fault finding procedure corresponding to the vehicle The diagnostic tool can detect the following short circuits on the multiplex network e short circuit between CAN L and 12 V e short circuit between CAN H and 12 V e short circuit between CAN H and earth e short circuit between CAN L and earth e short circuit between CAN L and CAN H open circuits Note In the case of a short circuit between CAN L and earth communication between the various computers which make up the multiplex network is not interrupted However the multiplex network becomes sensitive to interference and can be the cause of an intermittent fault After having located the multiplex line fault it is possible to repair it whilst applying all the necessary precautions outlined in this document 88B 1 MULTIPLEXING Multiplex network Repair 88 B IMPORTANT Do not untwist the harness to be repaired more than 100 mm D The wires at E must be twisted uniformly along the repaired length 3 Repairing the multiplex line IMPORTANT Before starting to repair a multiplex line it is necessary that you familiarise yourself with the use of the tools relating to this repair see 88A Wiring Wiring repair kit Use
26. it for the sleeve to cool before manipulating it to maintain the quality of the solder minimum sok f If the 2 wires have identical diameters twist waiting period 1 minute together the stripped section of the 2 wires E before putting them into the sleeve Do not bend the sleeve even when cool so as to not damage the quality of the solder or the sealing properties of the sleeve Note Do not move during installation Do not overheat the sleeve Do not move the sleeve or wires until they have cooled If several self solder sleeves must be positioned repeat the operation sleeve by sleeve When the heating operations have finished move on to the checking operation see 88A Wiring Wiring Check If the 2 wires have different diameters wind the 4 Crimp sleeves stripped section of the smaller wire around that of the larger wire F before inserting them in the sleeve Note For a wire to wire join go straight to the crimping operation Special notes for joining 2 wires to 1 wire IMPORTANT Do not use if a tight seal is needed engine and underbody areas and damp areas of the doors and boot 88A 21 WIRING Wiring Repair S8A Crimping Repeat the crimping operation on the other end of the sleeve to obtain the result below The equipment necessary and the wires are ready for the crimping operation Take the crimping pliers Squeeze the handles fully
27. nect the pyrotechnic component 1 Identify the solution The case in question must figure in the table below Otherwise replace the wiring Airbag and pretensioner components Under seat connector Shunt the connector See Under seat connector in this section Airbag warning light on Pyrotechnic component Replace the connector using the airbag connectors kit See Pyrotechnic connectors squib airbag component connectors in this section triggers pretensioner etc Airbag computer connector No operation Change the wiring harness except in the following cases f there is a specific procedure OTS along with the authorisation to apply it e f the connector lock is broken lock replacement authorised Airbag and pretensioner harness No operation except in specific conditions See Airbag and Pretensioner damage harness damage in this section IMPORTANT Any repair linked to the airbag function necessitates a specific check using the network s diagnostic tools 88C 1 AIRBAGS AND PRETENSIONERS Airbag and pretensioner wiring Repair 2 Under seat connector When fault finding identifies an under seat connector fault shunt the under seat connector following the procedure below Cut the electrical wires either side of the connector Apply the specific procedure for repairing multiplex lines see 88B Multiplex Multiplex network Repair except the part on locating the fault to shunt the connector Note
28. operation wires A and C denote the wires which are found at either side of the sleeve In the case of a 2 to 1 type operation wires A and B denote the 2 wires which are found at the same side of the sleeve C denotes the single wire on the other side 88A 18 WIRING Wiring Repair S8A 2 Preparation 3 Self solder sleeves To start the preparatory stage check that the wiring is sufficiently accessible and that the sleeves have been chosen Note Fit the self solder sleeves connection and heating line by line sleeve by sleeve Detach the wires from the wiring Check that the operating area is sufficiently Connection spacious and that the sleeves can be fitted staggered if there are several wires The equipment necessary and the wires are ready for the operation Mark the wires to be cut particularly if there are several wires the same colour Slip the self solder sleeve onto one of the wires Cut the damaged wire s Stagger the cuts if a lot Connect the wires by twisting the stripped sections of wires are marked so that the sleeves are not all around each other on top of each other The cut must be made at a distance of no less than 50 mm from the damaged section and in an area where the sleeve will remain straight Cut the replacement wire to length s identical to those removed from the harness If the self solder sleeves are being used add 30 mm for the wire joints
29. ot use this solution when a tight seal is needed engine and underbody areas and damp areas of the doors and boot Ee n m y 113089 e Wire cross sections Note This is stage 2 when using the label See the sleeve choice table taken from the label Note The columns corresponding to the wire cross sections give a representative overview of the different cases Identify the cross section of the wire which is the subject of the operation Use the diagram showing pictures of wires which correspond to the wire cross sections Check that the diagram is at scale 1 Find the section of the stripped wire 88A 15 WIRING Wiring Repair 0 35 min 0 5 mm 0 75 mm 1 mm Hh Refer to the columns of wire cross sections to find its case Note If the case in question is not present refer to the special cases Example 1 Joining 2 wires each 2 mm together 1 to 1 type operation Look at the upper section of the columns 1 to 1 Each wire A and C has a 2 mm section Refer to the line where column A shows 1 x 2 mm and column C shows 1 x 2 mm2 Example 2 Joining 3 wires together 2 to 1 type operation Look at the lower section of the columns 2 to 1 On one side the 2 wires A and B both have a 1 mm section On the other side wire C has a 2 mm section Refer to the line where column A amp B show 2 x 1 mm2 and column C shows 1 x 2 mm2 88A Id
30. r sleeve differentiated by the colour of their rings G Clear for a copper cross section sum of 2 wires The heat gun is a hot air blower with 2 nozzles which between 0 3 and 0 8 mm in total enable it to be adapted for different needs Concentrator nozzle E 77 11 237 778 Red for a copper cross section sum of 2 wires Heat shield nozzle F 77 11 237 777 between 0 8 and 2 0 mmZ2in total It can be used to solder all self solder sleeves and to Blue for a copper cross section sum of 2 wires contract the heat shrinkable parts and sheaths on all between 2 0 and 4 0 mm in total sleeves Its temperature and flow of air are adjustable and are These are sealing sleeves The seal is formed by the indicated on the screen rings which tighten around the wire when heated Temperature adjustment from 80 C to 650 C by increments of 5 C These sleeves are only to be used for connecting one Air flow adjustment from 200 I min to 550 I min at wire with another wire 1 to 1 5 levels displayed on the screen The operating instructions for this kit are described in this document see 88A Wiring Wiring repair kit Use 88A 7 WIRING Wiring repair kit Description 88A Crimping sleeve e Adhesive PVC tape Use the adhesive PVC tape for taping the wires Do not use it to protect or insulate electrical parts It is a contact adhesive high temperature tape Coil of twisted wires 113084 There are t
31. r all components or electrical connections which have a connection to the functions or equipment listed For example For the electric power assisted steering the function is not specified It is prohibited to carry out operations on any wire attached to the electric power assisted steering The recommendations for the specific cases take precedence over the general cases For example For an operation on a pair of twisted wires general case for the airbag function specific case the specific case refers back to the repair procedure for Airbags and pretensioners and the general cases refer back to the repair procedure for multiplex lines It is the specific cases which take precedence follow the referral to the repair procedure for Airbags and pretensioners Specific cases Functions or components Diesel or petrol engine Pedal potentiometer Change the wiring and transmission assembly Cylinder sensor Change the wiring Rail pressure regulator Change the wiring Fuel flow actuator on the pump Change the wiring Throttle valve connections Change the wiring Multiplex network see 88B Multiplex Multiplex network Repair Airbags and pretensioner Under seat connector see 88C Airbags and Pretensioners Airbag and Pretensioner Wiring Repair Airbag detonator squib see 88C Airbags and Pretensioners Airbag connector and Pretensioner Wiring Repair Pretensioner squib connector see 88C Airbags and Pretensioners Airba
32. re show signs of damage at N caused by overheating Note Reconnect the battery see the MR corresponding to the vehicle 80A Battery Battery Removal Refitting 2 Check with the diagnostic tool When a repaired line can be tested with the diagnostic tool run this check 3 Function check Check that the component or the function of the repaired line is working correctly If the case in question requires it carry out a test drive Note Always check for faults after repair Refer to the fault finding procedure for the function concerned 88A 4 Fitting and protection After the operation reposition the wires concerned in the main harness tape up the main harness using adhesive tape protect the harness as it was originally using equivalent noise or anti damage or superior protection with the protections recommended by the Parts Department IMPORTANT Any repair which requires a special heat shield for the wiring are forbidden Replace the wiring harness IMPORTANT Check that the wiring is correctly secured and protected to avoid any wear by rubbing and any noise disturbance 5 Final check After any operation on a wiring harness check that there are no faults with the diagnostic tools Clip EasyClip etc Refer to the corresponding fault finding procedure If a fault is present pass on the vehicle fault finding to a qualified operator automotive electrician techni
33. together to unlock the pliers and open the jaws see 88A Wiring Wiring repair kit Use On the pliers find the crimping jaws which correspond to the sleeve chosen Insert the wire s into one end of the sleeve up to the stop located inside the metal barrel of the sleeve Position the pliers jaws around the middle of the section of the metal barrel where the wire s are 115687 The pliers have correctly crimped each wire on the halves of the metal barrel at G without damaging the plastic Squeeze the handles fully together to crimp the sleeve onto the wire s Crimping is complete once the pliers are opened again IMPORTANT Check that the copper of the wire is correctly crimped and that the plastic part of the sleeve has not been cut If the wire has been stripped by the correct length and correctly inserted in the metal barrel then the copper of the wire should barely jut out from the shaft Note If the wire is not correctly crimped cut the wire before the sleeve and start the operation again with a new sleeve 88A 22 WIRING Wiring Repair Heating the crimp sleeve Switch on the heat gun fitted with the concentrator nozzle after familiarising yourself with the precautions for use see 88A Wiring Wiring repair kit Use Set the temperature and the air flow to the values indicated following the procedure in this note see 88A Wiring Wiring repair kit Use Ch
34. umbers Label The label affixed inside the case is made up of 4 sections printed in English and French In the upper section at A is the title and number of the note In B are the After Sales part numbers for the network and MABEC code for factories which enables the kit to be restocked with consumables or new tools or a new kit to be ordered In the lower section C is a table not exhaustive which helps in selecting the correct sleeve with a summary of the recommendations for each case And in D are the recommendations for use 88A 2 Tools Stripping pliers 77 11 230 416 These are automatic pliers which enable an electrical conductor up to a maximum cross section of 6 mm to be cut or stripped The length of the stripped section can be adjusted up to 20 mm The operating instructions for this kit are described in this document see 88A Wiring Wiring repair kit Use e Crimping pliers 77 11 230 417 The crimping pliers have three sizes of jaw red blue and yellow which correspond to the crimp sleeves These pliers are recommended for the crimping the sleeves provided in the kit The operating instructions for this kit are described in this document see 88A Wiring Wiring repair kit Use 88A 6 WIRING Wiring repair kit Description 88A Heat gun 77 11 230 415 3 Consumables Self soldering sleeves There are three sizes of heat shrinkable self solde
35. utting edges e Cutting a wire To cut electrical wires up to 6 mm insert the wire into slot A and press the handle 88A 9 88A Stripping a wire This pair of stripping pliers is automatic It does not need adjusting to the cross section of wire to be stripped 6 mm maximum To strip a wire adjust the length to be stripped by moving the stop B Press lightly on the ends to make it slide The length to be stripped is read on the scale C in millimetres mm Adjust the stripping pressure by moving the cursor D Press on the cursor to make it slide The further forward the cursor is the greater the force NOTE If the pressure is too weak the cutting edges will not grip the wire s insulation If the pressure is too strong the cutting edges can cut through the copper strands Start with a medium setting and then adjust according to results Place the end of the wire against the stop B and bring it out through the jaws E Press the handle The jaws will grip the wire The cutting edges will automatically adjust their position in relation to the section of wire and strip it NOTE Check the quality of the stripped wire insulation cleanly removed and no cut copper strands Start again if necessary WIRING Wiring repair kit Use 2 Crimping pliers The crimping pliers are the only pliers recommended for crimping the crimp sleeves in the kit They are used on the 3 sizes of crimp sle
36. wire The temperature setting is 340 C If 2mm lt section 1 section 2 lt 4 mm use the self solder sleeve with blue rings Strip 15 mm from each wire The temperature setting is 400 C Conditions for crimp sleeves Consider the section of each wire separately 2 use the red lf 0 5 mm lt each section lt 1 5mm crimp sleeve Strip 7 mm from each wire The temperature setting is 280 C 2 use the blue lf 1 5 mm lt each section lt 2 5mm crimp sleeve Strip 7 mm from each wire The temperature setting is 300 C If 3 mm2 lt each section lt 6 mm2 use the crimp sleeve Strip 8 mm from each wire The temperature setting is 320 C 88A Case of a wire joint between 2 wires and 1 wire less common situation Conditions for crimp sleeves Add together the 2 wire cross sections copper strands found on one side of the sleeve to find Sum side 1 If 0 5 mm lt Sum side 1 lt 1 5 mm And if 0 5 mm lt wire cross section side 2 only lt 1 5 mm2 use the red crimp sleeve The temperature setting is 280 C If 1 5mm lt Sum side 1 lt 2 5 mm And if 0 5 mm lt wire cross section side 2 only lt 1 5 mm2 use the blue crimp sleeve The temperature setting is 300 C If3 mm2 lt Sum side 1 lt 6 mm And if 0 5 mm lt wire cross section side 2 only lt 1 5 mmZ2 use the yellow crimp sleeve The temperature setting is 320 C For stripping the wires 7 mm is strippe
37. ws wiring connector kits to be used All electrical cables and wires with cross sections between 0 35 mm and 6 mm except sensitive lines defined in this document are affected IMPORTANT Repair of sensitive lines is prohibited using the generic procedure alone This repair can be authorised on condition that it is complemented with a suitable procedure see 88A Wiring Wiring Precautions for repair The technical nature and the sensitivity of this type of operation requires the adapted equipment contained and described in the Wiring repair kit case NOTE Using tools or components which have not been recommended is strictly forbidden when repairing wiring IMPORTANT For sensitive lines only automotive electricians technician agents or cotechs Level 2 Electricity as a minimum can carry out the repair described in this note 88A 2 Terminology e Wiring connector kit Kit usually made up of a connector the cells of which are fitted with crimped wires along with sleeves for joining Multiplex lines or connections Principal or secondary CAN network lines linking the computers together and made up of twisted pairs of stranded wires e Turns or twists For twisted pairs One turn twist A x lt POxcp 88A 5 WIRING Wiring repair kit Description 1 Case and label Case 77 11 229 893 The case contains all the components described in this section A label lists their part n
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