Register Login
Save up to 15% with Adrian Flux insurance!
Reply
 
Thread Tools
Old 23-02-2019   #1
Join Date: Aug 2018
Posts: 8
Thanks: 2
Trader Rating: 0
United Kingdom 
Fiat 500 tailgate wiring - fixed!

Hi All - I appreciate that this has been covered before but having fixed my daughter's car this morning I thought I would share this as I suspect many other people will have similar issues.

My daughter has had her 2008 Fiat 500 for a couple of years now. The demister has never worked, just blowing fuses, there has been issues with the number plate lights and I'm pretty sure at one time the rear windscreen wiper was controlled by the demister switch. Anyway, a couple of weeks ago a fuse blew, after shutting the boot, and the speedo stopped working. She got really upset and I thought it was time we did something about it.

We had traced the fault to the wiring loom where it enters the boot - a common issue for the 500

So we bought this repair kit made by Vemo.

https://www.onlinecarparts.co.uk/vemo-875647.html

And followed this guide (albeit it is for a different car, but same principal).


I cut out the original rubber wire harness between the cars body and the tailgate to reveal the wires. I was a little shocked by what I saw so I took the attached photo. There are 14 wires in total plus the tube for the washer. Every wire had split its insulation revealing the bare wire. Two wires had broken right through. No wonder the electrics were playing up.

The Vemo repair kit was surprisingly of a higher quality that I expected and I would recommended. The wires are very flexible (and contain multiple very fine stranded wire) which highlights the issue. Fiat has fitted very un-flexible wire in a area that needs to flex each time the boot is shut. I'm not at all surprised the wires have all broken. The kit actually had 15 wires, I'm guessing in case there is a reversing camera fitted.

The repair kit is fitted with bullet crimping connectors, again these are of a decent quality.

To fit, you need to be brave and cut all the wires in the car, chop out the broken section and then crimp on the repair kit. I took my time as it is not hard, but there is not a lot of room for wire strippes and the crimping tool. I also took of the trim from the back of the boot lid. This allowed me to free up the wiring loom and pull more through to get a bit more space.

All the fiat wires are colour coded as is the repair kit, but not with the same colours. So take your time and crimp one wire at a time so you don't get them mixed up.

Once done, its just a matter of pushing the wires and crimps back into the body of the car, and tailgate. Refitting the trim on the boot and pushing the rubber harness into place.

It's a fiddly job, but not hard. I found it easier with my cheap basic crimping tool and wire stripper rather than my more fancy (but still cheap) ratchet ones. The ratchet ones are more bulky and I couldn't get them into the space.

Anyway, if you are suffering electrical problems, hopefully this may give an idea of how it can be fixed.

Rob
Attached Thumbnails
Click image for larger version

Name:	IMG_20190223_140806.jpg
Views:	134
Size:	105.9 KB
ID:	198113  
Thanks Gina500, varesecrazy thanked for this post
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

Burgerbob is offline Reply With Quote Quote 
Old 28-02-2019   #2
Join Date: Mar 2011
Location: Berkshire, UK
Posts: 1,285
Thanks: 80
Trader Rating: 0
United Kingdom 
Re: Fiat 500 tailgate wiring - fixed!

Very useful post, Bob. Out of interest, is the wire in the repair kit more flexible than the original wire?
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

TrevC is offline Reply With Quote Quote 
Old 01-03-2019   #3
Join Date: Feb 2019
Location: Luxembourg
Posts: 15
Thanks: 0
Trader Rating: 0
Luxembourg 
Re: Fiat 500 tailgate wiring - fixed!

Bob, that is absolutely brilliant. I am this week dealing with the same issue. I have posted my problem and was pointed to your post.

https://www.fiatforum.com/500/471909...m-big-one.html

A small point. You mention your basic tools a crimper and wire stripper. I presently don’t have either so would appreciate a photo of yours as you mention size is important!
Thank you.
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides


Last edited by Gfplux; 01-03-2019 at 19:47.
Gfplux is offline Reply With Quote Quote 
Old 03-03-2019   #4
Join Date: Aug 2018
Posts: 8
Thanks: 2
Trader Rating: 0
United Kingdom 
Re: Fiat 500 tailgate wiring - fixed!

Quote Originally Posted by TrevC View Post
Very useful post, Bob. Out of interest, is the wire in the repair kit more flexible than the original wire?
Yes - the wire in the repair kit is massively more flexible that the wiring in the loom. It's made up of multiple very fine strands of wire, compared to much thicker strands of wire in the loom.

Comparing the two, it was no surprise that the fiat loom broke.
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

Burgerbob is offline Reply With Quote Quote 
Old 03-03-2019   #5
Join Date: Aug 2018
Posts: 8
Thanks: 2
Trader Rating: 0
United Kingdom 
Re: Fiat 500 tailgate wiring - fixed!

Quote Originally Posted by Gfplux View Post
You mention your basic tools a crimper and wire stripper. I presently donít have either so would appreciate a photo of yours as you mention size is important!
Thank you.
Many thanks

Knowing I had to do plenty of stripping and crimping I used the excuse to buy myself better quality tools.

On the right in the picture you can see my new ratchet crimping tool and strippers. I'm sure these are very good, but too bulky to use in the space. My old cheap ones on the left worked fine, it was still a little fiddly but manageable.

Removing the trim from the boot and pulling the wire through to get more space was vital. It may be possible to strip down the trim at the back of the car to free up the wiring loom from the car side, but I managed without doing this.

The kit comes with two pieces of heat shrink, I couldn't figure out what these were for at the time but it dawned on my afterwards. You have to cut and rejoin the tube for the rear washer. The heat shrink is to put over the join to seal it. I just used some duct tape and it was fine.

Hope it goes well!
Attached Thumbnails
Click image for larger version

Name:	IMG_20190303_160227.jpg
Views:	33
Size:	2.12 MB
ID:	198311  
Likes Sunday, Gfplux, varesecrazy liked this post
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

Burgerbob is offline Reply With Quote Quote 
Old 03-03-2019   #6
Join Date: Feb 2019
Location: Luxembourg
Posts: 15
Thanks: 0
Trader Rating: 0
Luxembourg 
Re: Fiat 500 tailgate wiring - fixed!

Thank you. A great help.
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

Gfplux is offline Reply With Quote Quote 
Reply
Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump
Similar Threads
Thread Thread Starter Forum Replies Last Post
(T) Tailgate wiring Iggy64 Tipo (Classic) 32 14-02-2019 20:35
(G) Headroom on the 2016 Fiat 500 Lounge (fixed glass roof) walterh 500 11 15-02-2016 22:49
(T) Tailgate lock wiring tinmar49 Panda 2 20-01-2014 18:05
(G) Fiat 500 Tailgate (rear door) not closing properly. DougLyon 500 7 28-06-2011 18:52