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Old 16-09-2014   #31
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Re: Hatch wiring cables

Quote Originally Posted by Andy Monty View Post
which is why i suggested keeping any joints away from the hinged area the heat shrink should support the join..

remember things like the heated rear screen has a much higher load than the boot catch wiring or the number plate lights... so wire must be load specific
Would you know the amp load on the wire for heated screen ? I am considering doing this myself, but may just get the repair loom from Germany. Don't worry digging the information, I will look up the fuse ratings a bit later.

EDIT : 30A, here is a previous post https://www.fiatforum.com/500/313588...ml#post3130353
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Last edited by arorat; 16-09-2014 at 17:51. Reason: 30a
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Old 16-09-2014   #32
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Re: Hatch wiring cables

Quote Originally Posted by arorat View Post
Would you know the amp load on the wire for heated screen ? I am considering doing this myself, but may just get the repair loom from Germany. Don't worry digging the information, I will look up the fuse ratings a bit later.

EDIT : 30A, here is a previous post https://www.fiatforum.com/500/313588...ml#post3130353
Posting a question & then answering it yourself - love it .

If you do get that German loom repair kit, do let us know how you get on - I'm thinking you could just cut everything in the middle (it even has a patch for the rear screenwash hose), attach the repair kit & feed both ends back into the respective bits of bodywork. If so, that would likely make it the easiest way of fixing this all-too-common problem.
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Last edited by jrkitching; 16-09-2014 at 18:50.
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Old 16-09-2014   #33
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Re: Hatch wiring cables

Makes sense to cut it where the wires are broken, splice and push back.

If I do it, I will be calling you anxiously with sweat dripping and fancy wire cutters in other hand... which colour first, got 20 seconds left, which colour !!
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Old 17-09-2014   #34
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Re: Hatch wiring cables

Quote Originally Posted by arorat View Post
... which colour first, got 20 seconds left, which colour !!
Reminds me of "The Small Back Room" (1949 film) - a classic piece of high stakes reverse engineering
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Old 25-09-2014   #35
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Re: Hatch wiring cables

After making a trip to halfords and Maplins I opted for the loom from Germany.

There are 7 thickness of cables (14 cables and the water hose) the cables are very flexible and should last. I may just use the existing rubber housing and so not to cut the water hose, but lets see which one is more flexible.

@jrkitching thanks for the link

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Old 25-09-2014   #36
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Hatch wiring cables

What are coloured bits on the ends of the wires in "ze German kit", bullet connectors?
As an aside, in one of the many threads on this topic there is a list of items that Fiat recommend using with their official repair kit, they advise the use of heat shrink solder connectors, in three different sizes I think.
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Last edited by staffordmike; 25-09-2014 at 18:13.
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Old 25-09-2014   #37
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Re: Hatch wiring cables

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Old 26-09-2014   #38
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Re: Hatch wiring cables

Quote Originally Posted by staffordmike View Post
What are coloured bits on the ends of the wires in "ze German kit", bullet connectors?
As an aside, in one of the many threads on this topic there is a list of items that Fiat recommend using with their official repair kit, they advise the use of heat shrink solder connectors, in three different sizes I think.
the coloured bits in "ze German kit" are nano machines that accelerate dark matter, here is a pic.

The plastic covering is quite hard and looks like it can't be crimped, can you buy the male inserts with variable thickness ?

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Old 26-09-2014   #39
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Re: Hatch wiring cables

Odd, although from memory crimps can have rather hard plastic. Were there no instructions?

Could they be solder buckets?

Could be connectors, possibly "bullet" type?
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Old 26-09-2014   #40
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Re: Hatch wiring cables

Quote Originally Posted by zanes View Post
Could be connectors, possibly "bullet" type?
Looks like it to me, the colour denotes the size.

Google "Insulated Male Crimp Bullet Connector" and you'll find loads of them, colour coded by size to match the repair kit. You can get them off the shelf at Maplins & most likely any car parts outlet.
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Last edited by jrkitching; 26-09-2014 at 13:18.
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Old 26-09-2014   #41
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Re: Hatch wiring cables

Quote Originally Posted by zanes View Post
Odd, although from memory crimps can have rather hard plastic. Were there no instructions?

Could they be solder buckets?

Could be connectors, possibly "bullet" type?
Hi zanes, yes female bullet type connectors, the sleeve is very hard plastic and crimped on one end, after I posted the last post I thought if there is such a thing as a heat crimper !!

Edit: no instructions.

Quote Originally Posted by jrkitching View Post
Looks like it to me, the colour denotes the size.

Google "Insulated Male Crimp Bullet Connector" and you'll find loads of them, colour coded by size to match the repair kit. You can get them off the shelf at Maplins & most likely any car parts outlet.
I wasn't sure of the wording for the insert part, "Bullet" it is.
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Last edited by arorat; 26-09-2014 at 16:49.
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Old 26-09-2014   #42
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Re: Hatch wiring cables

Given the price of that repair kit, I'd have thought they could have included the necessary male bullet connectors.

I guess most sales are made to professional auto electricians & they just assume that they'll have loads lying about.

Do let us know how easy (or otherwise) it is to use this kit - and come back again if you've any more questions.
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Last edited by jrkitching; 26-09-2014 at 17:18.
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Old 11-11-2014   #43
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Re: Hatch wiring cables

Quote Originally Posted by jrkitching View Post
Given the price of that repair kit, I'd have thought they could have included the necessary male bullet connectors.

I guess most sales are made to professional auto electricians & they just assume that they'll have loads lying about.

Do let us know how easy (or otherwise) it is to use this kit - and come back again if you've any more questions.
Had the loom replaced today 90 + vat from Paul at 001 Mobile in Walton upon Thames (opp old Merc showroom now VW). Loom was about 50 plus half a day of my time to get it sorted. Fiat in Croydon are quite pathetic and could not be bothered to return a call or respond to email, sadly this fault happened outside warranty otherwise grudgingly they would have obliged.

So a design issue on a car that is just 3 yrs old has cost me around 200... not good.

I think there needs to be a new thread for all owners with 500s under 3yr old to check the cables (5 minute job) and take the cars in to be repaired as the fault is likely to happen but unless Fiat fitted new flexible cables.
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Old 12-11-2014   #44
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Re: Hatch wiring cables

My cables just broke in the hatch for the 3rd time, i wonder what couses the wires to break..
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Old 12-11-2014   #45
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Re: Hatch wiring cables

Quote Originally Posted by cloud777 View Post
My cables just broke in the hatch for the 3rd time, i wonder what couses the wires to break..
Fiat use the wrong specification of wire for the application. It's caused by repeatedly bending wire that's not designed to be repeatedly bent.

Replacement with appropriately soft multistrand cables will fix the problem permanently.

I suspect many independent auto electricians don't use the right kind of wire when repairing these either.
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Last edited by jrkitching; 12-11-2014 at 13:11.
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