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

"The repair procedures given by the Manufacturer in this document are based on the
technical specifications current when it was prepared.
The procedures may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from
which his vehicles are constructed."

EDITION ANGLAISE

All rights reserved by RENAULT s.a.s.

Copying or translating, in part or in full, of this document or use of the service part
reference numbering system is prohibited without the prior written authority of
RENAULT s.a.s.

Renault s.a.s. 2005

ELECTRICAL WIRING REPAIR

Contents
Page

88A WIRING
Wiring: Precautions for repair
Wiring repair kit: General information
Wiring repair kit: Description
Wiring repair kit: Use
Wiring: Repair
Wiring: Check
Connector: Repair

88A-1
88A-5
88A-6
88A-9
88A-14
88A-23
88A-26

88B MULTIPLEXING
Multiplex network: Repair

88B-1

88C AIRBAGS AND PRETENSIONERS

Airbag and pretensioner wiring: Repair

88C-1

188A

WIRING
Wiring: Precautions for repair

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.

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 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.

1 - Result of the fault finding procedure.

Note:
During repair, check that you have the most recently
updated version of the Technical Note.

Note:
To check whether there is a wiring-connector kit,
consult DIALOGYS. These kits are generally linked
to specific wiring or function diagrams.

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).

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.

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.

88A

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).

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.

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.

Check that the fault is located more than 10 cm from

the connector.

88A-1

WIRING
Wiring: Precautions for repair

88A

2 - Specific procedures reference table.

Guidelines for reading the tables below:

If not otherwise stated, consider 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

Details

Instructions

Pedal potentiometer

Change the wiring

Cylinder sensor

Change the wiring

TDC sensor

See OTS

Rail pressure regulator

Change the wiring

Fuel flow actuator on the pump

Change the wiring

Injectors

Change the wiring

Throttle valve connections

Change the wiring

Coils

Change the wiring

Multiplex network

CAN

(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)

connector

(see 88C, Airbags and Pretensioners, Airbag

and Pretensioner Wiring: Repair)

Pretensioner (squib) connector

(see 88C, Airbags and Pretensioners, Airbag

and Pretensioner Wiring: Repair)

Airbag computer connector

(see 88C, Airbags and Pretensioners, Airbag

and Pretensioner Wiring: Repair)

Airbag sensor

Change the wiring

Other airbag lines

(see 88C, Airbags and Pretensioners, Airbag

and Pretensioner Wiring: Repair)

ABS sensor

Change the wiring

Other ABS lines

Change the wiring

Change the wiring

Diesel or petrol engine

and transmission
assembly

ABS

EPAS

88A-2

WIRING
Wiring: Precautions for repair

88A

General cases:
Functions or
components

Wiring harness

Details

Instructions

Number of damaged wires 10 or

fewer

(see 88A, Wiring, Wiring: Repair)

Number of damaged wires more

than 10

Change the wiring

Equipment and
predispositions specific to
commercial vehicles and
conversions

Change the wiring

Connections or
associated components

(see 88A, Wiring, Connector: Repair)

Splices

Splice with more than 3 wires

Change the wiring

3-wire splice which does not need

sealing

(see 88A, Wiring, Wiring: Repair)

Splice with 3 wires or more, which

needs sealing (engine and
underbody areas and damp areas
of the doors and boot)

Change the wiring

Sheathed wires

Change the wiring

Shielded wires

Change the wiring

Twisted wires

if the wire cross-sections are 0.5 mm 2:

(see 88B, Multiplex, Multiplex network:
Repair)

Flat cable

Change the wiring

Wires with specific thermal

protection

Change the wiring

Wires with copper cross-section

less than 0.35 mm2

Change the wiring

Wires with copper cross-section

greater than 6 mm2

Change the wiring

Wires damaged less than 10 cm

from the connector

(see 88A, Wiring, Connector: Repair)

Wires outside the loom

88A-3

WIRING
Wiring: 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
Technical Note or a removalrefitting procedure.

Sufficient accessibility?

YES

Remove the wiring.

Fault on a sensitive
line or equivalent?
(see table*)

YES

Is there a specific
procedure? (see
table*)

NO
YES

YES

Caused by
connector?

Is there a specific
kit? (DIALOGYS)

NO

NO

Is there a
connector kit?
(DIALOGYS)

YES

NO

NO

Fault more
than 10 cm from the
connector?

NO

YES

Procedure attached to
connector kit. (see table*)

NO

Fault more than

10 cm from the
connector?

YES

Generic repair procedure.

(see 88A, Wiring, Wiring:
Repair)

table*: Specific
procedures reference
table

Specific repair procedure. (see

table*)

Change the wiring.

88A-4

YES

WIRING
Wiring repair kit: General information

88A

1 - Purpose and applications.

2 - Terminology.

Description of the content of the Wiring repair kit case

as well as the procedure and the field of application.

Wiring-connector kit.
Kit usually made up of a connector, the cells of which
are fitted with crimped wires along with sleeves for
joining.

The kit enables wiring which is damaged or has cut

electrical wires to be repaired while retaining its
operating characteristics.

Multiplex lines or connections.

Principal or secondary CAN network lines linking the
computers together and made up of twisted pairs of
stranded wires.

It also allows wiring-connector kits to be used.

All electrical cables and wires with cross-sections
between 0.35 mm 2 and 6 mm2 , except sensitive lines
(defined in this document), are affected.

Turns or twists.
For twisted pairs:
One turn (twist) = (A)

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-5

WIRING
Wiring repair kit: Description
2 - Tools.

1 - Case and label.

88A

Case (77 11 229 893).

Stripping pliers (77 11 230 416).

The case contains all the components described in this

section. A label lists their part numbers.

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.

These are automatic pliers which enable an electrical

conductor up to a maximum cross-section of 6 mm 2 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).

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

Heat gun (77 11 230 415).

88A

3 - Consumables.

Self-soldering sleeves.

There are three sizes of heat shrinkable self-solder

sleeve differentiated by the colour of their rings (G):
Clear, for a copper cross-section (sum of 2 wires)
between 0.3 and 0.8 mm2 in total.

The heat gun is a hot air blower with 2 nozzles which

enable it to be adapted for different needs:
Concentrator nozzle (E), (77 11 237 778).
Heat shield nozzle (F), (77 11 237 777).
It can be used to solder all self-solder sleeves and to
contract the heat-shrinkable parts and sheaths on all
sleeves.
Its temperature and flow of air are adjustable and are
indicated on the screen.
Temperature adjustment from 80C to 650C by
increments of 5C.
Air flow adjustment from 200 l/min to 550 l/min at
5 levels displayed on the screen.

Red, for a copper cross-section (sum of 2 wires)

between 0.8 and 2.0 mm2 in total.
Blue, for a copper cross-section (sum of 2 wires)
between 2.0 and 4.0 mm2 in total.
These are sealing sleeves. The seal is formed by the
rings which tighten around the wire when heated.
These sleeves are only to be used for connecting one
wire with another wire (1-to-1).

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

Crimping sleeve.

88A

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.

There are three 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 mm2 .
Blue, for a copper cross-section between 1.5 and
2.5 mm2 .
Yellow, for a copper cross-section between 3.0
and 6.0 mm 2.
These are sealing sleeves. The seal is formed by the
inner wall which becomes adhesive when heated.
These sleeves can be used to join one wire with
another wire (1-to-1) or two wires with another wire
(2-to-1).

This is a coil of a twisted pair of wires (40 turns/

linear m). Ensure these wires remain twisted.
The 2 wires have a 0.5 mm 2 cross-section and are of
temperature class T3. It is possible to fit them in all
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.

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 2 maximum).

1 - Stripping pliers.

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).

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 cutting edges.

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.

Cutting a wire:

To cut electrical wires up to 6 mm2 , insert the wire into

slot (A) and press the handle.

88A-9

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.

88A

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.
The crimping pliers are the only pliers recommended
for crimping the crimp sleeves in the kit.

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.

They are used on the 3 sizes of crimp sleeve:

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-10

Note:
If the wire is not correctly crimped, cut the wire at the
sleeve and start the operation again with a new
sleeve.

WIRING
Wiring repair kit: Use
3 - Heat gun.

88A

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 selfsolder sleeves in the kit.

IMPORTANT
Before using the gun, the user must familiarise
themselves with the safety advice in the user's
manual provided by the manufacturer.

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.

Introduction to the gun:

The heat gun is recommended for contracting heat

shrinkable sleeves.
For other applications, the user must take the
precautions and advice in the user's manual into
account.

General information on the setting parameters:

Description of the heat gun:

(I) = 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

WIRING
Wiring repair kit: Use

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.

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

88A

WIRING
Wiring repair kit: Use

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.

88A-13

88A

WIRING
Wiring repair kit: Use

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 150C 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

88A

WIRING
Wiring: Repair

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
not use this solution when a tight seal is needed
(engine and underbody areas and damp areas of the
doors and boot).

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 selfsolder sleeves.

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 crosssections 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 crosssections.
Check that the diagram is at scale 1.
Find the section of the stripped wire.

88A-15

WIRING
Wiring: Repair

88A

Identifying 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).
Refer to the columns of wire cross-sections to find its
case.

As relates to the previous examples.

Example 1.
2 possible sleeves:
Either the blue self-solder sleeve.
Or the red crimp sleeve.

Note:
If the case in question is not present, refer to the
special cases.
Example 1.
Joining 2 wires, each 2 mm2 , 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 2 section. Refer to the
line where:
column A shows 1 x 2 mm2 ,
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 mm2
section. On the other side wire C has a 2 mm2 section.
Refer to the line where:
column A & B show 2 x 1 mm2 ,
and column C shows 1 x 2 mm2 .

Example 2.
Only the blue crimp sleeve is possible.

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

Case of a wire joint between 1 wire and 1 wire

(most common situation).

88A

Case of a wire joint between 2 wires and 1 wire

(less common situation).

Conditions for self-solder sleeves:

Conditions for crimp sleeves:

Add together the 2 wire cross-sections (copper

strands):

Add together the 2 wire cross-sections (copper

strands) found on one side of the sleeve to find Sum
side 1.

If 0.3 mm2 (section 1 + section 2) 0.8 mm2, use

the self-solder sleeve with clear rings.
Strip 10 mm from each wire.
The temperature setting is 300C.
If 0.8 mm2 (section 1 + section 2) 2 mm 2, use the
self-solder sleeve with red rings.
Strip 12 mm from each wire.
The temperature setting is 340C.
If 2 mm2 (section 1 + section 2) 4 mm2, use the
self-solder sleeve with blue rings.
Strip 15 mm from each wire.
The temperature setting is 400C.

If 0.5 mm 2 Sum side 1 1.5 mm2.

And if 0.5 mm 2 wire cross-section side 2 only
1.5 mm 2, use the red crimp sleeve.
The temperature setting is 280C.
If 1.5 mm 2 Sum side 1 2.5 mm2.
And if 0.5 mm 2 wire cross-section side 2 only
1.5 mm 2, use the blue crimp sleeve.
The temperature setting is 300C.
If 3 mm 2 Sum side 1 6 mm2.
And if 0.5 mm 2 wire cross-section side 2 only
1.5 mm 2, use the yellow crimp sleeve.
The temperature setting is 320C.

Conditions for crimp sleeves:

For stripping the wires:
Consider the section of each wire separately.
If 0.5 mm2 each section 1.5 mm 2, use the red
crimp sleeve.
Strip 7 mm from each wire.
The temperature setting is 280C.
If 1.5 mm2 each section 2.5 mm 2, use the blue
crimp sleeve.
Strip 7 mm from each wire.
The temperature setting is 300C.
If 3 mm2 each section 6 mm2, use the crimp
sleeve.
Strip 8 mm from each wire.
The temperature setting is 320C.

7 mm is stripped 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 crosssection.
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
Wiring: Repair

Settings table (taken from the label).

Sleeves

Self-solder
clear

red

1x0.35 mm2

1x0.35 mm2

10, 10

300

1x0.35 mm2

1x0.5 mm2

10, 10

300

1x0.5 mm2

1x0.5 mm2
1x1 mm

1x0.5 mm

blue

red

42
22 A+C

blue

2.5 2
0.52 A+B 1.52 1.5 2 A+B
1.52 & 1.52 C
2.52
& 0.52 C

2
2

12, 12

340

12, 12

340

7, 7

280

12, 12

340

7, 7

280

1x0.75 mm

1x0.75 mm

12, 12

340

7, 7

280

1x0.75 mm2

1x1 mm 2

12, 12

340

7, 7

280

1x1 mm2

1x1 mm 2

12, 12

340

15, 15

400

7, 7

280

15, 15

400

7, 7

280

7, 7

280

1x1.5 mm

1x1 mm

1x1.5 mm

1x1.5 mm

15, 15

400

1x1.5 mm2

1x2 mm 2

15, 15

1x2 mm2

1x2 mm 2

15, 15

1x2 mm

7, 7

300

400

7, 7

300

400

7, 7

300

7, 7

300

7, 7

300

1x2.5 mm
2

yellow
62
3 2 A+B
62
& 32 C

A, C
A, C
A, C
A, C
A, C
A, C
T (C)
T (C)
T (C)
T (C)
T (C)
T (C)
L (mm)
L (mm)
L (mm)
L (mm)
L (mm)
L (mm)

Crimp

0.8 2 0.82 A+C

22
0.32 A+C

Wire cross-sections

1
1

88A

1x2.5 mm

1x2.5 mm

1x3 mm2

1x3 mm 2

8, 8

320

1x3 mm2

1x4 mm 2

8, 8

320

8, 8

320

1x6 mm

1x6 mm

A&B
2x0.5 mm2
1x0.5 mm2 +
1x1 mm2
2
1 2x1 mm
2

A, B, C
A, B, C
A, B, C
A, B, C
A, B, C
A, B, C
T (C)
T (C)
T (C)
T (C)
T (C)
T (C)
L (mm)
L (mm)
L (mm)
L (mm)
L (mm)
L (mm)

1x1 mm 2

10, 10, 7

300

1x1.5 mm2

10, 7, 7

300

10, 7, 7

300

1x2 mm 2

10, 10, 7

300

1x2 mm 2

10, 7, 7

300

1x0.5 mm +
1x1.5 mm2
1x0.5 mm2 +
1x3 mm2
2x2 mm2

1x3 mm 2

11, 8, 8

320

1x6 mm 2

11, 11, 8

320

mm

Stripping/Temperature

mm

mm

mm

mm

mm

In the case of a 1-to-1 type 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

88A

3 - Self-solder sleeves.

2 - Preparation.
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

spacious and that the sleeves can be fitted
staggered (if there are several wires).

Connection.

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

of wires are marked so that the sleeves are not all
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.

Connect the wires by twisting the stripped sections

around each other.

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.
IMPORTANT
The cross-section of replacement wire must not
be less than the original cross-section of wire.
IMPORTANT
Use a 0.5 mm 2 wire to repair a 0.35 mm2 wire.
IMPORTANT
The temperature class of the replacement wire
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

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
section of the wires must be located between the
2 sealing rings (B).

WIRING
Wiring: Repair

88A

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 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
IMPORTANT
Wait for the sleeve to cool before manipulating it
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.

88A

When joining 2 wires to 1 wire, first connect the 2 wires

from the same end in the following way:
If the 2 wires have identical diameters, twist
together the stripped section of the 2 wires (E),
before putting them into 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
stripped section of the smaller wire around that of
the larger wire (F) before inserting them in the
sleeve.

4 - Crimp sleeves.
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

Crimping.

88A

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
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.
Squeeze the handles fully together to crimp the
sleeve onto the wire(s). Crimping is complete once
the pliers are opened again.

The pliers have correctly crimped each wire on the

halves of the metal barrel at (G) without damaging the
plastic.

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.

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.

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).

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.

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.
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).

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

Result of a correctly applied crimp sleeve.

1 - Visual checks.

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.

(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

self-solder sleeve at (K) during contraction.

IMPORTANT
The various struck-through cases are strictly
forbidden.
The self-solder sleeve has not been correctly shrunk.
At (I), 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).

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 wire show signs of
damage at (N) caused by overheating.

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.
Note:
Reconnect the battery (see the MR corresponding
to the vehicle, 80A, Battery, Battery: Removal Refitting).

IMPORTANT
Check that the wiring is correctly secured and
protected to avoid any wear by rubbing and any
noise disturbance.

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.

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).

Note:
Always check for faults after repair.
Refer to the fault finding procedure for the function
concerned.

88A-26

WIRING
Connector: Repair

88A

IMPORTANT
The colour of the wires cannot serve as a marker.
In certain cases, wiring-connector kits can have
different colours to those of the wiring to be
repaired.

IMPORTANT
Apply this procedure when there is a connectorwiring 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.

cut the connector wires to be replaced to a length

greater than 100 mm and stagger the cuts,

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).

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,
the self-solder or crimp sleeves necessary for the
repair,
other components specific to the function
concerned (e.g. fuses).

3 - Checking and fitting the repair with wiringconnector kits.

2 - Using a wiring-connector kit.

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).

Except in the specific outlined cases, use the wiringconnector kits as follows:
4 - Final check.

check that the kit is complete,

check that the connnector configuration (position

of wires in the cells of the connector) corresponds
to your needs,

check that the wire cross-sections of the wiringconnector kit are equal to or larger than the crosssection of wires to be repaired,

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).

mark the wires to ensure that the tracks are not

reversed,

88A-27

188B

MULTIPLEXING
Multiplex network: Repair
2 - Necessary equipment.

IMPORTANT
This procedure relates to the repair of the
multiplex network alone (twisted wires).

For repairing the multiplex network, use the

components of the wiring repair kit (see 88A, Wiring,
Wiring repair kit: Description).

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:

88B

short circuit between CAN L and + 12 V,

short circuit between CAN H and + 12 V,
short circuit between CAN H and earth,
short circuit between CAN L and earth,
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
3 - Repairing the multiplex line.

88B

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.

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).
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 mm2, 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
To join the wires, working wire by wire:
slip the self-solder sleeve onto the wire,
twist the end of the wires together.

88B

Refer to the precautions for use relating to self-solder

sleeves (see 88A, Wiring, Wiring: Repair).
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
30 s 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 efficient the
heating is.

IMPORTANT
The colour of the wires (CAN H et CAN L) must
be respected when they are being joined.

Position the sleeve with its solder ring in the centre of

the wire joint.

Switch on the heat gun.

Adjust the temperature of the gun to 340C 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

NOTE
Wait for the sleeve to cool before manipulating it
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.

MULTIPLEXING
Multiplex network: Repair
4 - Checking the multiplex line.

88B

No turns (twists) at (H).

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.

The two wires added are of a different length.

Apply the recommendations from the generic repair

procedure concerning the fitting and fuses (see 88A,
Wiring, Wiring: Check).
IMPORTANT
The various struck-through cases are strictly
forbidden.

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).

88B-4

AIRBAGS AND PRETENSIONERS

288C
Airbag and pretensioner wiring: Repair

88C

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, disconnect 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

Solutions

Under seat connector

(Airbag warning light on)

Shunt the connector. See Under seat connector in this section.

Pyrotechnic component
connectors (squib) (airbag
triggers, pretensioner, etc.)

Replace the connector using the airbag connectors kit. See Pyrotechnic
component connectors in this section.

Airbag computer connector

No operation. Change the wiring harness except in the following cases:

If there is a specific procedure (OTS), along with the authorisation to apply
it.
If the connector lock is broken, lock replacement authorised.

Airbag and pretensioner harness

damage

No operation except in specific conditions. See Airbag and Pretensioner

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.

88C

Find the colour of the connector: Blue, green or

orange.

When fault finding identifies an under seat connector

fault, shunt the under seat connector following the
procedure below:

Find the shape of the connector: Straight or angled.

Select the same connector (colour and shape) from
the airbag connectors kit (see under DIALOGYS).

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.

Example of an angled SQUIB connector.

Note:
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.

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.

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-2

AIRBAGS AND PRETENSIONERS

Airbag and pretensioner wiring: Repair
4 - Airbag and Pretensioner harness damage.

5 - Airbag lines repair check.

Confirm the airbag line repair to ensure that the repair
is correct:

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 mm2 , 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

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 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