Wiring Bundle Repair

[Jeremy Palenchar]

I have completed the wiring diagram, the parts list, and the procedure
on how we did this. Send me email if you would like the files.


-Jeremy

_______________________________________________
Email: mailto:jeremyp at mindspring.com

The Solution is in the Question, not the Answer
_______________________________________________

-----Original Message-----
From: 200q20v-admin at audifans.com [mailto:200q20v-admin at audifans.com] On
Behalf Of Jeremy Palenchar
Sent: Monday, July 08, 2002 4:28 PM
To: 'Jeremy Palenchar'; 'Sullivan, Alan'; 200q20v at audifans.com
Subject: RE: Wiring Bundle Repair


OK,

I put together a parts list for the materials I used to rebuild the
harness in my driver's door.

The grand total was $175 (including a $35 crimping tool).

This could be done for much less using Molex 15 position plugs but I
think the AMP connectors are built better and provide a more secure
connection.

I could put together a kit for $200 + shipping if a few people are
interested. Please email me if you would like the parts list.


-Jeremy

_______________________________________________
Email: mailto:jeremyp at mindspring.com

The Solution is in the Question, not the Answer
_______________________________________________

-----Original Message-----
From: 200q20v-admin at audifans.com [mailto:200q20v-admin at audifans.com] On
Behalf Of Jeremy Palenchar
Sent: Monday, July 08, 2002 11:11 AM
To: 'Sullivan, Alan'; 200q20v at audifans.com
Subject: RE: Wiring Bundle Repair


Hi Alan,

A fellow 200 owner and I have replaced this wiring harness. It is not an
easy job but the cost is approx. $100 and will take about 8 hours labor.
I have a spreadsheet that describes all of the wires that run through
the door and I can put together a parts list if anyone is interested.
The procedure involves cutting the harness at each end and installing a
new harness that has quick-disconnect plugs.

It may be possible to remove the door panel and the wire ties behind it
to get some additional slack to repair the old wiring.

Let me know if you would like the plans for the new harness.


-Jeremy

_______________________________________________
Email: mailto:jeremyp at mindspring.com

The Solution is in the Question, not the Answer
_______________________________________________

-----Original Message-----
From: 200q20v-admin at audifans.com [mailto:200q20v-admin at audifans.com] On
Behalf Of Sullivan, Alan
Sent: Monday, July 08, 2002 6:34 AM
To: 200q20v at audifans.com
Subject: Wiring Bundle Repair


Several of the wires in the wiring bundle between the driver's door and
the body are broken, right where they flex as the door opens and closes.
Fixing them will be difficult, as they are bundled together rather
tightly.  Any suggestions on how to get some slack into the wires for
repair?  Also, any opinions on how best the make the repairs ---
soldering (how do I do that without melting insulation on other wires)
versus crimped-on connectors or some other method?

Alan Sullivan
Northern Va
91 200TQ
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