193K miles and still
Join Date: Oct 2005
Re: 2 or 4?
To replace the wires in the rubber tube between the boot and the body below the rear window.
The job is quite straightforward as long as you can solder OK and are not colour-blind because you will need to be able to identify the colours correctly at both ends when you replace the wires in between.
You will need a soldering iron, solder, thin rubber or plastic sleeving to cover the soldered joints, side cutters, wire strippers, light coloured insulation tape to write on and suitable auto wire which has to be at least as thick as the thickest wire in the loom being replaced.
1) If you have the radio codes etc disconnect the battery earth in the boot.
2) Carefully pull back the rubber at the boot end and body end.
3) The thicker orange of the two is the thickest cable being replaced. Use whatever colour you have.
4) Gently pull the rubber back at the boot end so that you have at least 2" of wires showing and cut all cables (10) at 45 degrees - not straight across - you will need to stagger the soldered joints.
5) You can now remove rubber tube and see how damaged your cables are. Most of mine just fell to bits.
6) Cut again just below the window where the wires enter the car again at 45 degrees leaving at least 2" as you need something to solder to.
7) Cut the first of your new cables, I made mine 2" longer than the total length of rubber it was going into. About 10" in my case.
8) Starting at the boot end, strip back the first existing cable about 3/8", twist and tin and push on about 1" of tube insulation.
9) Strip, tin and solder new wire to existing and pull back insulation to cover the soldered joint you have just made.
10) Repeat for all 10 wires.
11) Stick a small piece of insulation tape at each of the loose ends where they are to join onto the cables below the back window.
12) Identify the colour at the boot end of each wire and write it on the insulation tape at the other end. As long as you understand it that is the important thing because you will have to be able to match to the colours of the cables coming out below the window. I used "SO" for small orange and "LO" for large orange etc.
13) Now the hardest bit. Tape over all the joins and covering insulation sleeves at the boot end. Mine ended up being about 1/2" thick.
14) Tape the other end of your cables because now you have to thread the new cables thorough the rubber tube ready to solder at the window end. I used a thick wire through first and used that to pull the new bunch through. Voila!
15) Because you wrote on each wire what colour was what you can now one by one cut, tin and solder below the window carefully identifying and matching each cable colour as you go. Don't worry if the cables are a bit long as there is plenty of room below the rear parcel shelf to accommodate any excess.
15) Tape up the insulated soldered connections at the window end.
16) Attach the grommit an each end of the rubber tube back in its original position at the boot and below the window.
17) Check boot opening and closing so that nothing is trapped.
18) Connect battery and test.
A tedious job but not too difficult and just the cost of a few electrical bits,time and the odd burn of course!
Hope this makes some sort of sense next time I will take pictures!