5NP-P8K4P-07

GROUP
BODY
ELECTRICAL
Technical Service Bulletin
DATE
NUMBER
17-BE-006
MODEL(S)
JUNE, 2017
SUBJECT:
ALL
GUIDE FOR WIRING HARNESS AND CONNECTOR REPAIR
This bulletin supersedes TSB 15-BE-004 to update the wiring connector ordering information.
Description: This TSB provides information for wire harness connector repair. This TSB has been
developed to improve customer satisfaction by simplifying the repair of electrical wire harnesses. It
can also save costs and improve dealer service capabilities by making repairs more efficient than
the replacement of an entire harness assembly.
Applicable Vehicles: All Vehicles
NOTICE
If the estimated cost of the connector repair exceeds the cost of replacing the
harness, then it is advisable to replace the wire harness.
!
CAUTION
Do not perform any connector repair that is related to a seatbelt or restraint system.
Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair
SUBJECT:
GUIDE FOR WIRING HARNESS AND CONNECTOR REPAIR
Tools required:
Multi-Purpose Crimper:
- A: Stripper
- B: Crimper
Stripper
Heat Gun
Soldering Iron
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GUIDE FOR WIRING HARNESS AND CONNECTOR REPAIR
Shrink tube
Inline Connector
Electrical Tape
Solder
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GUIDE FOR WIRING HARNESS AND CONNECTOR REPAIR
Parts Information:
PART NAME
PART IMAGE
TRK CONNECTOR KIT
(Lighter Blue)
ORDERING CONTACT
INFORMATION
This kit was released to dealers
in 2002. It is no longer
available to order.
This kit was released to dealers
in 2008. It is no longer
available to order.
WRK CONNECTOR
KIT
This kit was released to dealers
in 2013.
WRKII
(Darker Blue)
To order WRKII kit contact
Bosch at (866) 539-4248 and
order item #G0KHN002.
If an individual connector is
needed, reference pages 6 - 8
of this TSB to determine if
connector is available and
order through MOBIS.
Process for connectors
not found in TRK,
WRK, or WRKII kit
Example
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GUIDE FOR WIRING HARNESS AND CONNECTOR REPAIR
Warranty Information:
Labor Cost Use TT code (Actual Time) for warranty claim submission of the repair.
When the wiring repair connector (WRK II) is used for warranty repair, the parts cost
is as follows:
Part Cost
Parts Cost Reimbursement = (Qty. of Connectors Used) X ([Unit Price X Mark-up])
Harness Replacement Guidelines:
Replace the wiring harness only when the vehicle has one of the following conditions:
• The wiring harness is related to a seatbelt or restraint system.
• The vehicle is damaged by flood, fire, or rodents.
• The vehicle is involved in a heavy crash that requires major body rework.
• The wiring connector is not available in Wiring Repair Connector Kit (WRK II).
• The wiring harness replacement is required for a campaign completion.
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GUIDE FOR WIRING HARNESS AND CONNECTOR REPAIR
WIRE CONNECTOR KIT INFORMATION
TRK (2002)
WRK (2008)
WRKII (2013)
WIRE CONNECTOR SEARCH INSTRUCTIONS
1. Go to www.hyundaitechinfo.com and Select Connector I.D.
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GUIDE FOR WIRING HARNESS AND CONNECTOR REPAIR
2. Select the number of cavity(slots).
3. Select the connector which matches your search.
NOTICE
If a red part number is provided, then the connector can be found in the TRK, WRK,
or WRKII wire connector kit.
If a red part number is not provided, then order the connector through Mobis using
the provided part number in black.
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GUIDE FOR WIRING HARNESS AND CONNECTOR REPAIR
Mobis part number
(black) which must
be ordered through
Mobis (normal
ordering system).
Part number (red) of
connector which can
be found in the TRK,
WRK, or WRKII kit.
Wire size (mm)
Amount of cavities
Types of terminals
(M = male or F = female)
NOTICE



The complete TRK and WRK connector kits are no longer available.
To order a complete WRKII connector kit, contact Bosch (866) 539-4248.
If an individual connector is needed, reference pages 6 - 8 of this TSB to determine
if connector is available and order through MOBIS.
WIRE HARNESS CONNECTOR REPAIR PROCEDURE
1. Disconnect the battery negative (-) terminal
(A).
NOTICE
Record the customer’s AM, FM
and XM radio stations before
disconnecting the terminal.
TSB #: 17-BE-006
A
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GUIDE FOR WIRING HARNESS AND CONNECTOR REPAIR
2. Strip off the friction tape wrapped around the
connector or wire to be repaired.
3. Cut off at the appropriate spot (B) the wires
to be repaired, starting with the No. 1 wire
and completing the full repair procedure to
the No. 1 wire before cutting the next wire to
be repaired.
!
B
CAUTION
Perform the connector replacement
only 1 wire at a time to avoid any wire
confusion/mix up.
4. Using a wire stripper, strip off about 10mm
(C) of the vinyl coating of each end of wire.
!
CAUTION
Make sure that the wire-stripping and
gauge-crimping slots are properly
matched.
C
If the slots do not match, the wire
may be damaged and may not fit into
the connector.
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GUIDE FOR WIRING HARNESS AND CONNECTOR REPAIR
5. Insert the shrink tube (D) into the wire of the
connector to be repaired.
D
6. Using the inline connector (E), connect the
wire from the vehicle side to the wire from
the repair connector side.
E
7. Crimp the inline connector (F) by using the
multi-purpose crimper.
!
CAUTION
F
Choose the correct gauge-crimping
slot for the repair; otherwise, it may
cause damage to the wire.
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GUIDE FOR WIRING HARNESS AND CONNECTOR REPAIR
8. Gently pull both ends of the wires to check
that the wires are tightly secured.
9. Solder the wire.
!
CAUTION
Use care when soldering to avoid
heat damage to wiring, connector,
surrounding components and trim of
the vehicle.
10. Reposition the inserted shrink tube (G)
centering over the middle of the pressed
solder connector and shrink the tube by
using a heat gun.
!
G
CAUTION
Fully cover the repaired area with the
shrink tube.
The shrink tube should be securely
wrapped around the soldered
connector.
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GUIDE FOR WIRING HARNESS AND CONNECTOR REPAIR
11. Use the same procedures for the other wires
completing one at a time. Be sure to stagger
the repairs as shown to avoid enlarging the
harness and creating insufficient
connections.
!
CAUTION
Wrap electrical tape to indicate the
unused wires.
Be careful not to strip off the vinyl
coating off the end of the unused
wires in the repair connector.
12. Reconfirm that the wires are connected as
specified in the appropriate electrical
troubleshooting manual (ETM) circuit
diagram.
Example
13. Apply the electrical tape (H) to the entire
bundle of wires. Leave a gap of about 50
mm (2.0 in.) long from the end of the
repaired connector.
50 mm
(2.0 in.)
H
NOTICE
Before applying the tape, verify
that each wire is connected to its
proper location.
!
CAUTION
If the electrical tape is applied too
closely to the end of the repair
connector, the wires may become
dislodged from the connector due to
stress.
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GUIDE FOR WIRING HARNESS AND CONNECTOR REPAIR
14. Connect the negative (-) battery terminal.
I
15. Wiggle test the repaired area to confirm
integrity of the circuit. Check for normal
operation of the electrical system related to
the repaired connector.
16. Connect the GDS and verify if any incidental
Diagnostic Codes (DTC) have been created
by the repair.
Clear all the DTC (s) if the repair has been
confirmed fixed.
17. If applicable, clear any DTCs in the Blue Link
system per instructions of TSB 12-BE-005-2.
18. Program customer’s radio stations and
confirm all systems are operational.
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