EPC wiring repair

If you have some experiance with electrical wire repairs and have the right tools for the job then you can do it. If you are not sure of what to really do then have the dealership do the repair. According to the service bulletin you would need to cut out the old harness and connector and splice in the new connector and wires. Each wire will require you cut a certain length so you do not have a bunch of butt connectors side by side making it impossible to put the harness back in the wire loom. I will post the pictures and procedure. Read it over and if you feel you can do the repair then good luck with the repair. If you feel you can not, then I would strongly recommend you take it in to the dealership or an automotive electrician specialist?

Affected Vehicles

Condition
01 09 04 Feb. 18, 2009 2018652 Supersedes T. B. Group 01 number 08 25 dated Sept. 18, 2008 due to additional model year and additional engine applicability.

MIL ON, DTCs P1545, P0121, P0123, P0221 or P0222 Stored in ECM Fault Memory

Malfunction indicator lamp in instrument cluster is illuminated.
A number of incident memory entries with regard to the throttle valve are stored in the ECM. In most cases, the entries are sporadic.

Technical Background
Contact resistance in the ECM wiring - throttle valve.

Production Solution
Optimized wiring and contacts.

Service
Wiring Harness and Connector Repairs, General Information

Tip :- Observe general notes for repairs of vehicle electrical system, see Repair group 97 Wiring in ElsaWeb.
- DO NOT solder repairs on vehicle electrical system.
- DO NOT repair crimp connectors. If necessary, over lay a wire parallel to inoperative wire.
- After crimping a repair connection, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.
- Yellow wires are to be used exclusively for wiring harness repairs.
- Mark repaired areas using yellow adhesive tape.
- Yellow wires and areas in wiring harness wrapped with yellow adhesive tape identify a previously performed repair.
- Perform a function test after each repair. If necessary, check DTC memory, erase and/or bring systems into basic setting.

Procedure - Switch Ignition OFF.
- Disconnect battery ground (GND) cable, see Repair Manual Group 27 in ElsaWeb.

WARNING: The steps above must be completed to ensure safety during repair. Also, observe all country-specific regulations.

Use the applicable repair manual in Elsa in addition to the description below. Check ETKA to determine if you need set 1 or set 2.

- Lengthen wires and preassemble seals according to Figure 1.

- Release lock on new wiring harness end connector housing using small flathead screwdriver. Use slot marked in Figure 2.
- Insert all terminals into housing until they audibly click.
- Reinstall lock.

- Using an appropriate assembly tool, slide the single wire seal up repair wire until it contacts housing. Continue to slide seal into housing as far as the stop (Figure 3).

Strip wires 6-7mm using tool VAS 1978/3. Install crimp connectors using crimping pliers (base tool) -VAS 1978/1-2 with head VAS 1978/1-1 (Figure 4).
- Remove car harness insulation to appropriate length (approximately 24cm).
- Lay new harness beside old harness. Cut original wires to fit new harness.
- Twist wires 3 and 5 and 1, 2, 4 and 6 as they were originally.
- Crimp connections.
- Use shrink tip (VAS 1978/15) with hot air gun 220 V/ 50 Hz (VAS 1978/14) to complete installation of shrink tubes.

NOTE: When heat-shrinking crimp connections, care must be taken not to damage any other wiring, plastic components or insulating material with hot nozzle of heat gun. Always observe operating instructions of heat gun.

- Re-insulate harness with yellow tape.
- Check proper function. If necessary, check DTC memory, erase and/or bring systems into basic setting.

NOTE: If faults reoccur after repair, replace main throttle.