Wire Repairs
WARNING: This page is about a different car, the 2000 Volvo S80 and 1999 Volvo S80. However, it is still accessible from the selected car via links, so may be relevant.
- Before performing wire repairs, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM .
- Wire harness repairs must only be performed at specified locations. See Fig 1 , Fig 2 , Fig 3 , Fig 4 & Fig 5 . Disconnect circuit connectors. Cut wires to ensure enough wire is available to splice harness. Cut wires so there is 1.5" (40 mm) between wire ends. Ensure no other wires are cut.
- Twist new and old wire harnesses at least 2.4" (60 mm). See Fig 6 . Place at least 3.2" (80 mm) of heat-shrink tubing over one end of wires. Strip insulation at least 0.2" (5 mm) from end of each wire.
- Twist wire core on each wire end. Put one end of wire in Crimping Sleeve (951 2783). Using Press Tool (951 2785), crimp wire in crimping sleeve. Repeat for each wire. Using Hot Air Gun (951 2777), place putty knife behind wire and shrink crimping sleeve tubing. See Fig 7 . Repeat for each crimping sleeve end.
- Slip heat-shrink over crimping sleeves. Using hot air gun and putty knife, shrink heat-shrink tubing. Repeat for splice.
- Reconnect connectors. Ensure there is no harness tension. Secure spliced wire harness to SRS harness outside harness wrap with cable tie or tape. Activate SRS system. See DISABLING & ACTIVATING AIR BAG SYSTEM .
WARNING:
Before removing terminals from connector end, note location of each wire in connector housing. Failure to retain original terminal location may result in SRS system component deployment and/or personal injury.