Harness Repair Procedure: Inspection

Harness Repair Website and Resources

Wiring Harness and connector repair information including disassembly videos are located on the Harness Repair website. Links are found in ASIST and in the eWD. The website contains the following information:

Picture of connector with color, cavity quantity and connector family.
Part number of connector and part number of crimped terminal wire, if available.
Wire gauge and applicable solder sleeve.
Tool(s) required for procedure
Animation of removal procedure: Terminal locking tab location, removal of the retainer, and removal of the terminal

NOTE:

The crimped terminal wires, included in the kits, are the maximum gauge approved for use with the terminal. This wire may be larger than the existing wire in the vehicle.
The replacement connector body or wire color may differ from the original color.

Connector Information

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Description

No.	Item	Description
1	Connector number	Alphabetic characters show to which harness the connector is placed. Numeric characters show the identification number of connectors.
2	Connector type	: Connector model : Cavity : Male (M) and female (F) terminals : Connector color : Special type	Courtesy of NISSAN NORTH AMERICA, INC.
3	Connector color	This means the color of a connector.
4	Terminal number	This means the terminal number of a connector.
5	Wire color	This shows a code for the color of the wire.
		B = Black W = White R = Red G = Green L = Blue Y = Yellow LG = Light Green BG or BE = Beige BR = Brown	LA = Lavender OR or O = Orange P = Pink PU or V (Violet) = Purple GY or GR = Gray SB = Sky Blue CH = Dark Brown DG = Dark Green
		When the wire color is striped, the base color is given first followed by the stripe color as shown below: Example: L/W = Blue with White Stripe
6	Connector	This means the connector information. This unit-side is described by the connector symbols.

Using the Retainer/Terminal Removal Tool

Retainer/terminal removal tool use varies depending on which connector type is being serviced. Read all of the notes provided above prior to beginning a repair.

Performing terminal removal and installation should be easy. Watch the video and Read each step before beginning the procedure. Not reading each step may cause damage to connector retainer or locking tabs. Determine whether the terminal locking tab is integral into the connector or the terminal - this will affect the direction of the motion required to release the terminal.
Perform tool selection carefully - though a tool may appear to be the right shape, it may not be the correct tool for the connector.
Use of two blades (with spacer between them) will be required to release some terminals.
Unless otherwise directed, position the blade so the long side is against the connector.
In some cases, the wire must be pushed into the connector slightly to relieve pressure applied to the locking tab by the terminal. Not relieving this pressure may prevent the terminal from becoming unlocked.

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Retainer/Terminal Removal Tools

Retainer/Terminal Removal Tool
NI-48817-1 Retainer/Terminal Removal Tool
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NI-47003-11 Retainer Removal Tool
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NI-47003-14 through NI-47003-35 Terminal Only Removal Tools(Use correct tool for the connector. Examples: NI-47003-14, NI-48817-25, NI-48817-29))
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Using the Spread Terminal Gauge (STG)

Select the correct STG for the terminal to be tested.
Align the tip of the STG with the terminal.
While moving the connector slightly, gently apply pressure to the STG.
If the STG enters the terminal without compressing, replace the terminal.
- If crimped terminal wire is not available, replace the connector assembly.
- If neither part is available replace harness.
NOTE: Do not attempt to modify/compress crimped terminal wire.
To view the video on a STG pass/fail test got to the harness repair website or follow the link in ASIST or in the eWD.

NOTE:

Use the Spread Terminal Gauge (STG) to inspect female terminals for loose fit.
Visually inspecting terminals is insufficient - using the STG test is the best method.
Use of the wrong STG may give inaccurate test results or cause damage to the terminal.
Refer to the Harness Repair Site to determine which STG should be used for each terminal.

Spread Terminal Gauges (STG)

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Bulk Wire

Bulk wire is available from Nissan in five sizes to make a correct repair. If the exact size is not available, go up one wire size. Nissan bulk wire is Hi-Temp and can be used in exterior or interior applications.

NOTE:

Using Nissan wire is required for warranty repairs.

Use solder sleeve chart, as reference for proper wire/solder sleeve application.

Automatic Wire Stripper

CAUTION:

To avoid the risk of minor personal injury:

Always wear approved eye protection to prevent eye injury.
Do not use non-insulated, plastic-dipped or slip-on plastic handles that are NOT intended for protection against electrical shock without the proper PPE, to prevent electrocution.
Never repair live electrical circuits, to prevent electrocution.

Automatic Wire StripperPart # NI-35615

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Wire Stripper Repair Procedures
NOTE: To avoid damaging the wiring harness, be careful not to cut the wires when using automatic wire strippers. On small gauge wire (gauge 26-30) manual wire strippers are recommended.

The following procedure describes how to use the automatic wire stripper, to remove insulation from the wire without nicking or fraying.
1. Choose and install the correct stripper die for the wire gauge you are repairing.
2. Adjust the wire stop to the desired stripping length. The recommended length for Blue Solder Sleeves (12-16 AWG) is approximately 10 mm (0.4 in.).
3. With the open side of the jaws toward you (wire stop to the right), place the wire in the appropriate size stripping hole with the end touching the wire stop. Refer to the blade for AWG and mm size markings.
4. Squeeze the handles together to strip the wire. Release pressure from the handles and remove the wire.

Solder Sleeves

CABLE SIZE(GAUGE AWG)	SOLDER SLEEVE COLOR	SOLDER SLEEVE IMAGE
26-30	White	Courtesy of NISSAN NORTH AMERICA, INC.
18-24	Red	Courtesy of NISSAN NORTH AMERICA, INC.
16-12	Blue	Courtesy of NISSAN NORTH AMERICA, INC.

Solder Sleeve Installation Steps

IMPORTANT: Jacketed and/or shielded wires cannot be repaired.

Check the gauge of the wire that is to be spliced, to determine correct solder sleeve size.
Strip approximately 10 mm (about 3/8 inch) of insulation from the wires that will be attached.

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Slide the Solder Sleeve over one of the wires that will be connected.
Twist the two wires together

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Position the solder ring in relation to the twisted wires.

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NOTE: For the next step, do not use an electric type soldering tool. An electric type soldering tool may generate a current that can damage a control unit that might be connected to the circuit.
"Install" the solder sleeve connector by shrinking it to the wire with essential tool Flameless Heat Gun NI-46538 or similar flameless heating tool. "Installing" the solder sleeve connector will:

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- Melt the solder (silver ring inside the solder sleeve connector) into the exposed twisted wire area.
- Melt the sealant (white, red or blue rings inside the solder sleeve connector) onto the wires.
- Shrink the remainder of the solder sleeve connector to the wire.

NOTE:

When repairing a wire bundle that has been damaged it works best to stagger the solder sleeves:

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Miscellaneous Supplemental Service Parts

OE replacement parts available: body clips, felt tape and corrugated tubing/loom.

Part	Application	Nissan Parts Available	Picture
Electrical Tape	Cover solder repairs, secure wire loom	No	-
Body Clips	Interior use to prevent squeaks, rattles, chafing Several Size Available	Yes	Courtesy of NISSAN NORTH AMERICA, INC.
Felt Tape	Interior use to prevent squeaks, rattles, chafing	Yes	Courtesy of NISSAN NORTH AMERICA, INC.
Wire Loom	Protect exterior wires, available in 2 sizes: 3/8" and 5/8"	Yes	Courtesy of NISSAN NORTH AMERICA, INC.

There are 2 corrugated tubing tools that are used to aid in the installation of corrugated tubing:

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Tools are available through Nissan Tool and Equipment Website.

Harness Replacement Guidelines

IMPORTANT: Observe all applicable safety precautions described in the service information for the electrical systems that are being repaired. Replace the wiring harness ONLY when the vehicle concern involves any one of the following conditions:

The wiring harness circuits are related to HEV / EV High Voltage.
The estimated cost of the repair exceeds the cost of replacing the entire wiring harness.
The vehicle is damaged by flood or thermal incident.
The wiring harness was severely damaged due to a car accident.
The appropriate components are not available to order.
The wiring harness replacement is required from another TSB.
The wiring harness repair is in the shielded area of a circuit.
The wiring harness needing repair is USB, Coaxial, or Antenna Feeder wiring.