SRS Wiring - Replacement Available
SECTION3
GROUP
37
NO.
917
DATE
Jan. 1997
RE:
Replacing SRS wiring
960, 1995-
REFERENCE:
TP 3701201, SECTION 3(37) WIRING REPAIRS AND REPLACEMENT OF CABLE TERMINALS; 850, 900
TP 32231/1, SECTION 8(88), SRS (AIRBAG); 940/960 1993-
Replacing SRS wiring
Background:
On the 960 from model year 1995, SRS wiring is included in the passenger compartment wiring harness. To avoid replacing the entire passenger compartment wiring harness when the SRS wiring is damaged, replacement SRS wiring is available. This is installed separately in the passenger compartment. Cables between the car's electrical system and the crash sensor are connected with moisture proof splicing sleeves as described in this Service Bulletin. Use only these moisture proof splicing sleeves when repairing the SRS wiring.
Cut off connectors on the existing SRS wiring. Replacement wiring has suitable connectors.
Note:
Do not cut cables without removing connector to airbag unit.
There are 2 different versions of the SRS replacement wiring as follows:
960, model year 1995 9447368-3
960, model year 1996- 9447372-5
Other material required:
tie straps 948211-8
tie straps 948616-8
Moisture proof splicing sleeve 9130467-5
Electrical tape
Replacing SRS wiring
Preparations
Secure the SIPS-bag. See Service Manual:
Section 8(88) "SIPS-bag" 960 1996-
Remove:
- Left and right front seats. Position seats as far back in the passenger compartment as possible.
- Disconnect negative battery lead.
- Left soundwall panel.
- Left B-pillar panel.
- Left sill.
- Left kick panel.
- Left front floor carpet.
- Left air duct for rear floor heating.
- Upper and lower steering wheel covers.
- Right soundwall panel.
- Right B-pillar panel.
- Right sill.
- Right kick panel.
- Right front floor carpet.
Install new cable harness
Disconnect and cut off existing connector by SRS sensor.
The illustrations show the connector from model year 1996-. The shape and color of the 1995 connector is different. See illustration.
SRS sensor connector color:
M/Y 1995 Violet
M/Y 1996- Green
Cut the sleeve on the cable harness up approx. 300 mm (12").
Cut off the four larger cables at the end of the slit.
Insulate the cut cable ends with electrical tape.
(The four smaller cables will later be spliced onto the new wiring.)
Take out the new cable harness
Connect connector to SRS sensor.
Route the short cable at the first cable harness junction to the left seat belt tensioner.
Route the cable forward in an arc up to and along the existing seat belt tensioner wiring.
The long section of cable harness should follow the route of the cable harness to the left-hand side of the center console.
Secure the new cable harness with tie straps, P/N 948211-8, to the existing cable harness. Do not tighten the tie straps yet.
Splice the new and old cable harnesses
The four small cables on the new cable harness have different lengths. Cut down the four small cables on old cable harness to fit the new ones. When the cables have been spliced the splicing sleeves should not be side by side.
Strip 4-5 mm (3/16") insulation from the 4 + 4 cables on the old and new cable harnesses.
Splice cables of the same color from the old and new cable harnesses. Use a moisture proof splice connector P/N 9130467-5.
Splicing cables is described in:
Service Manual Section Section 3(37) "Wiring repairs and replacement of cable terminals" 850 900 section KC.
Take care not to damage cable insulation when heating splice connectors.
Use a high temperature for the shortest possible time.
Check that the cable insulation has not been damaged by heating and that the adhesive inside has extruded out of the splice connector around the insulation.
When the cable splices have cooled, position them inside the spliced protective sleeve.
Seal the protective sleeve with electrical tape.
Disconnect the existing connector by the left seat belt tensioner. Cut off the existing cable in the passenger compartment cable harness 110 mm (45/16") from connector.
Insulate the cut cable end with electrical tape.
Connect the new cable harness connector to the seat belt tensioner.
Disconnect the existing 2-pin steering wheel module connector and cut off the cable (approx. 130 mm (5-1/8") including connector) where it connects to the existing cable harness.
Insulate the cut cable end with electrical tape.
Route the cable with the green connector (orange for the 1995 model) above the knee bolster (if installed) from the new cable harness junction, to the left of the center console and on to the ignition switch. (B in the illustration. below)
Route the new cable harness along the ignition switch, the same way as the old one, and connect it to the 2-pin steering wheel module connector.
Route the remaining cables (A) from the junction to the left of the center console in front of the relay box (B) on the right-hand side of the center console.
Position that section of the new cable harness intended for the right seat belt tensioner under the air duct for rear floor heating.
Route the cable from the air duct to the seat belt tensioner along the existing cable and secure it in the mountings for the existing wiring.
Disconnect the existing right seat belt tensioner connector.
Cut off the existing cable 110 mm (4-5/16") from connector where it is joined to the other cables in the passenger compartment cable harness.
Insulate the cut cable end with electrical tape.
Secure the new cable harness to the air duct with tie straps P/N 948616-8.
Connect the new cable harness to the seat belt tensioner.
Position any excess cable harness under the air duct.
Passenger airbag
Remove glove compartment.
Disconnect the air duct under the glove compartment from the mounting on the heater. Fold it down to access the connector between the passenger airbag module and passenger compartment cable harness.
Route the cable with the red, 2-pin connector (violet in the cable harness for model year 1995) along the air duct to the passenger airbag module connector (located on the heater in front of the air duct).
Separate the connector between the existing passenger airbag module cable and the passenger compartment cable harness.
Cut off the connector on the existing passenger compartment cable harness.
Insulate the cut cable end with electrical tape. Connect the connector on the new cable harness to the passenger airbag module connector.
Reinstall the air duct and glove compartment.
Finishing works:
Check that the new cable harness is positioned so that it will not be damaged by wear and will not rattle.
If necessary, secure the cable harness with extra tie straps.
Tighten tie straps and cut oft loose ends.
Install:
- Left-hand side air duct to rear floor heating.
- Floor carpets
- Sills
- Steering wheel covers
- Cowl panels
- Soundwall panels
Turn the ignition switch to position II
Connect battery negative terminal.
Install front seats.
Rearm the SIPS bags.
See Service Manual Section 8(88) "SIPS-bag" 960 1996-.
Check that no SRS or other diagnostic trouble codes (DTCs) are stored in the on-board diagnostic (OBD) system.
Check SRS warning lamp in instrument cluster.
Remedy if necessary.
Set clock.
Enter anti-theft code on radio.
WARRANTY STATEMENT: Claims may be submitted under the New Car Limited Warranty when a manufacturing defect is present using claim type: 01
Operation No. Labor description Time allowance
37917-2 Replacing SRS wiring 2.2 hr