Wiring Harness And Connectors, Repairing

CAUTION!
Disconnect the battery Ground (GND) strap before working on the electrical system.

NOTE:
- Before disconnecting the battery, determine the correct coding for the anti-theft radio.
- After reconnecting the battery, check and activate the vehicle's electrical equipment (radio, clock, comfort and convenience features, etc.).

0.35 mm 2 Connector, Repairing

NOTE:
- There are three different repair connector thicknesses (0.5 sq.mm, 1.5 sq.mm, 4.0 sq.mm) with corresponding crimp connectors in the VAS1978 wiring harness repair kit.
- Use 0.5 sq.mm repair wire to repair a 0.35 sq.mm connector.
- The repair procedure is as follows:





- Strip end of 0.35 mm.sq wire connector to twice its length (approx. 12-14 mm) using wire stripper.
- Fold back half the length of bare metal part.
- Strip end of 0.5 sq.mm wire (approx. 6-7 mm) using wire stripper.





- Push crimp connector over wire ends and crimp on both sides using stop pliers.

The insulation on the connector ends may not be crimped.

- Make sure that the correct red crimping slot for 0.5 sq.mm is used.





- After crimping, crimp connector must be shrunk using hot air blower.

The crimp connector must be heated from the center towards both ends until it is completely sealed and the adhesive oozes out.

The hot-air blower must be set to the appropriate temperature in accordance with its operating instructions.

While shrinking, make sure that no other connectors, plastic parts or insulating material is damaged by the hot air jet.
- If repair connector was previously taped, this area must be taped again with yellow insulation tape. If necessary, secure wiring with new tie wraps.