febi has highlighted a frequent fault on the Fiat 500 and Ford KA II involving the failure of rear licence plate lamps, wipers, demisters, and tailgate latch sensors. These issues often lead to false alarm triggering or incorrect instrument panel warnings.
Technical Cause
The failure is typically caused by the wiring harness between the body and the tailgate becoming brittle over time. Regular opening and closing of the tailgate stresses the aged insulation, eventually resulting in cracks that lead to short or open circuits.
Repair Solution
The febi wiring harness repair kit (107102) utilises tinned, extra-fine wiring with silicone insulation. This material remains flexible at varying temperatures to prevent future cable breaks. The repair procedure involves:
- Testing: Conduct actuation and electrical tests to confirm the fault before disconnecting the battery.
- Installation: Cut the original harness to size and strip the insulation. Crimp the new wires into position, ensuring connectors are offset to avoid excessive loom bulk.
- Protection: Use the supplied flexible pipe to extend the rear-screen wash line. Wrap the assembly in fabric insulation tape (107140).
- Finalisation: Fit the new rubber gaiter and grommets. Reconnect the battery, clear any stored fault codes, and verify the operation of all affected systems.
For further technical data and application lists, visit partsfinder.bilsteingroup.com.
