Trunk Lid - Wiring Harness Chafing

CATEGORY
Electrical



SECTION
3



PAGE
34



ISSUE
10/92-0262



CODE
371



Subject:
Trunk Lid Wiring Harness

Application:
9000 CD



Replaces PSI 09/92-0252


NOTE:
THIS BULLETIN IS A COMPILATION OF THE INFORMATION CONTAINED IN PSI 06/92-0223 AND S.I. 11/89-1193 AND IS THE ONLY ISSUE THAT SHOULD BE REFERRED TO WHEN WORKING ON THE TRUNK LID WIRING HARNESSES.






To prevent possible wiring chafing or crimping in the trunk lid hinge, new wiring harnesses were introduced in production from VIN N1016871. This modified harness is now run outside of the trunk hinge, encased in a cable conduit (see Figure 1).


When investigating complaints of electrical component malfunction in the trunk area, or when replacing the trunk wiring harnesses, make certain the procedures outlined below are followed.


Cars Affected:

All 1989-92 9000 CD Models





Parts





When replacing the wiring harness, a complete conversion kit 85 48 554, (see Figure 2), as well as the required harnesses must be ordered. See parts microfiche for correct harness application information.



Action:

1. Remove the rear seat backrest.

2. Access the 8-pin and 2-pin connectors for the trunk lid wiring by folding the left-side trunk trim aside.





3. Unplug the 8-pin and 2-pin connectors. Disconnect the following leads in the male connectors (see Figure 3):

^ 8-pin connector: pin 1 (green)
pin 5 (brown)
pin 7 (black)


^ 2-pin connector: pin 1 (brown/white)
pin 2 (violet)





4. Cut the cable tie securing the wiring to the body (see Figure 4).





5. Remove and discard the plastic locating piece on the hinge (see Figure 5).



6. Remove the plastic cover from the hinge. Loosen the trim on the trunk lid at bottom left-hand corner.





Slacken the wire by drawing it through the hinge (see Figure 6).





7. Drill a 3 mm hole as shown in Figure 7, being careful not to damage the outer body panel. Also make certain to rustproof the hole when finished drilling.

NOTE:
On some late 1991 cars and 1992 models up to VIN N1016871, a stud is already welded in this location. If such a stud is there, it is not necessary to drill the 3 mm hole.





8. Holding the wire outside the hinge, strip off approximately 200 mm (approximately 8 inches) of the tape or protective sheathing (see Figure 8).

NOTE:
It is extremely important to strip off this protective tape or sheathing. If you do not, the wiring could possibly break due to flexing against itself.






9. Thread the wire through the corrugated cable duct 45 54 817. The cable tie should face towards the front of the car (see Figure 9).





10. Fit the corrugated cable duct into the cable conduit 43 53 538 (see Figure 10).





11. Clip the cable conduit to the hinge and re-run the wiring (see Figure 11).






12. The cable tie should be secured using screw 84 10 961 in the hole previously drilled, or, press the cable tie onto the stud already fitted (see Figure 12).





13. Install the cable tie with stud, 85 52 663 on the wiring harness and secure it in place (see Figure 13).





14. Reconnect the leads in the 8-pin and 2-pin connectors. Plug the connectors together (see Figure 14).



15. Verify that all electrical functions in the trunk area are operational (trunk light, taillights, etc.).

16. Refit the trunk trim, plastic hinge cover, trunk lid trim and the rear seat backrest.

Warranty Information:

For warranty repairs, use Failure Coding 37151-32-0-01-01. Time allowance is Labor Operation 37151 (0.9 hour) plus 0.2 hour entered in straight time.