Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
61 00... Notes on handling wiring harnesses and cables
The following applies in general:
To avoid damage, observe the following instructions:
- Avoid compressive and tensile loads
- Make sure cables are laid without kinks or abrasions
- Ensure non-contacting routing at sharp-edged body components; use edge protection if necessary
- Secure additionally laid cables/lines with cable straps
The following additionally applies
Shielded lines
Contact points in the shield can cause problems with regard to noise radiation and interference immunity. Consequently, distinctions have to be drawn between the following types:
Coaxial line
- Shielded RTK031 coaxial lines may only be repaired with special crimping tool for repairing the coaxial line.
CVBS lines
- CVBS lines may not be repaired.
- CVBS lines must be replaced in their entirety.
HSD lines
- HSD lines may not be repaired.
- HSD lines must be replaced in their entirety.
Optical fibre cable:
- Green = MOST (M edia O riented S ystems T ransport) optical fibre
- Yellow = ISIS (I ntelligent S afety I ntegration S ystem) optical fibre
- Orange = repair optical fibre cables
- Optical fibre cables are permitted to show only one separation point (bridge), replace optical fibre cables if necessary
- Smallest permissible bending radius is 25 mm
- Avoid influence of heat ≥ 85°
TREATING CABLES AND OPTICAL FIBRE CABLES
FlexRay:
It is possible to repair the FlexRay. In the event of damage, the cables can be joined with conventional BUTT CONNECTORS .
- The line is a twisted cable. If possible, maintain twist in line after repair.
Airbag lines:
Ribbon cables:
NO RELATED
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.