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I was doing some headlight works and I removed both headlights for the first time.
Thus I can see how the many other wires are routed and where are the chaffing potential.
I noticed MB Indonesia tie-wrap the wire for the wiper washer fluid level sensor at bit too tight.
As such when the LEFT headlight is installed, this wire actually rub tight to the headlight plastic body, hence I can see the shiny rub mark.
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Above and below. There is enough wire length to allow room for free play. It is just that the assembler person did not realized the headlight is so FAT and long at its azz.
So I added protection and give some wiggle room for this wire assy. I allow extra 2cm droop.
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Wire guide, plastic and secured only using Tesa 51036 and it can un-wind over time.
This is also found on windshiedl wiper washer hose, near the hood gas-ram cylinder.
Below is my refrigerant pressure sensor.
I noticed the TESA tape already dried and starting to un-wind.
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Give it new one and double, front and back. MB, BMW and Audi all use TESA tape. 2 types. One is Silencer and one other is chaffing protection, below is chaffing protection if 51036
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I want to share a simple trick.
Sometimes we can use the head of a cable-tie as a "bumper". See red arrow below. While I add new extra layer of TESA tape to risky region, specific to the area where
wire need to hit a 90 degree bend ( worst friction ), I like using cable-tie as extra "bumper".
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The RIGHT headlight cavity region is a bit different for the wire run. Not too bad.
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I use HVAC foam of 4mm here.
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So next time when you remove components on your car, pay attention to any wires which may have lost its securing clip or whatever NOT GOOD happening to it,
or imagine what can happen to it under high vibration etc etc.
Wounded wire causing short is not easy to find. so if we can prevent any potential chaffing, rubbing, pinching and whatnot...DO IT .
We used to use a consumable material called chafe strip. It was a Teflon impregnated plastic maybe 1/16inch thick. It came on a spool, but as it paid out it would deform into a helical resting state, to make it easier to wrap around areas prone to wire chafing, or hydraulic and fuel line chafing.
We used to use a consumable material called chafe strip. It was a Teflon impregnated plastic maybe 1/16inch thick. It came on a spool, but as it paid out it would deform into a helical resting state, to make it easier to wrap around areas prone to wire chafing, or hydraulic and fuel line chafing.
ohhh, yes I have that too. But Plastic mesh/net type and not cotton as cars do get wet.
Thanks LCG
If connector is still intact, such sleeve is not the best option as we need to slide the protection jacket in.
The plastic mesh/net one can expand a lot though. This one :
This was a big issue in aviation industry long while back, maybe still is. The plastic parts combined with vibration will eat thru aluminum and even steel given time. Hydraulic lines, cables, so on
06-30-2024, 05:16 AM
so if we can prevent any potential chaffing, rubbing, pinching and whatnot...DO IT .
