Wiring Harness: Service and Repair

Wiring Harness And Connectors, Repairing


CAUTION!
Before beginning repairs on the electrical system:
- Obtain the anti-theft radio security code.
- Switch the ignition off.
- Disconnect the battery Ground (GND) strap.
- After reconnecting vehicle battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows.


NOTE: See Battery, Disconnecting and Connecting procedure for the steps after reconnecting voltage supply.


General Information

Special tools and equipment







- VAS 1978 wiring harness repair kit


NOTE: Repairs to wiring harnesses and connectors must only be performed using the VAS 1978 wiring harness repair kit.







Detailed instructions on how to use VAS 1978 are supplied with the repair kit.

0.22 sq.mm or 0.35 sq.mm wire connection, repairing


NOTE:
- Repair kit VAS 1978 includes repair wires of three different thickness (0.5 sq.mm, 1.5 sq.mm, 4.0 sq.mm) with the corresponding crimp connectors.
- Use 0.5 sq.mm repair wire to repair a 0.35 sq.mm wire.
- Perform repair as follows:







- Strip off wire ends of 0.22 sq.mm or 0.35 sq.mm -wire using VAS 1978/3 wire strip pliers (approx. 12 to 14 mm).
- Fold back half way the stripped wire ends.
- Using stripping pliers, strip off ends of 0.5 sq.mm wire (approx. 6 to 7 mm).







- Push crimp connectors over wire ends and crimp at both sides with VAS 1978/1 crimping pliers.


NOTE:
- Be sure to use the correct crimping insert VAS 1978/24 (red color code for 0.5 sq.mm wires).
- Do not crimp insulation at end of wire.







- After crimping, seal crimping connector using VAS 1978/14 hot air blower and VAS 1978/15 sealing device.

Heat crimp connector from center outward until it is completely sealed and adhesive emerges.

Adjust hot air blower to appropriate temperature according to instructions.

When heating connector, be careful not to damage any other wiring, plastic parts or insulating material with the hot nozzle.

- If wire was originally wrapped, wrap it again using yellow insulating tape. If necessary, secure wiring using new cable ties.