Wire, 0.35 mm or Larger With Intermediate Wire Section, Repairing
Wiring Harnesses and Connectors
Special tools, testers and auxiliary items required
• Wiring Harness Repair Kit (VAS 1978) with
• Upgrade kit (VAS 1978/50)
• or Wiring Harness Repair Set (VAS 1978A)
• The Upgrade Kit (VAS 1978/50) is required to bring the "old" Wiring Harness Repair Kit ( VAS 1978) up to the new standard of the Wiring Harness Repair Set (VAS 1978A).
CAUTION!
• Wiring harness and socket repairs may only be carried out with the Wiring Harness Repair Kit (VAS 1978) or Wiring Harness Repair Set (VAS 1978A).
• Observe the country-specific requirements.
• Usage of the Wiring Harness Repair Kit (VAS 1978 ) or Wiring Harness Repair Set (VAS 1978A) is described extensively in the accompanying usage instructions.
• Repairs on open circuits and faulty connectors are also explained using examples.
Wire, 0.35 mm or Larger with Intermediate Wire Section, Repairing
• Only 0.5 mm2 repair wires are available for repairing a 0.35 mm2 wire.
Procedure
- Free up the wire to be repaired at two places approximately 20 cm on both sides of the repair point.
CAUTION!
Risk of damaging the electrical wires.
• Free up wrapped wiring harnesses carefully.
- If necessary, removing the wiring harness wrapping using a knife.
- Route yellow repair wire next to damaged wiring harness and cut repair wire to the required length using wire stripper ( VAS 1978/3).
- Cut damaged wire section from the vehicle-specific single wire.
- Adjust the sliding stop in the Wire Stripper ( VAS 1978/3) pliers jaws to 6 to 7 mm for the wire to be stripped.
- Insert the vehicle-specific single wire end from the front into the pliers jaws as far as the stop and squeeze the pliers together completely.
- Open pliers again and remove the stripped wire end.
- Repeat the procedure on the other end of the vehicle-specific individual wire.
- For the repair, use two suitable crimp connectors form the Wiring Harness Repair Set (VAS 1978A).
- Use the Crimping Pliers (Base Tool) (VAS 1978/1-2 ) to press the crimp connector.
The following exchangeable heads are available for the Crimping Pliers (Base Tool) (VAS 1978/1-2):
• Exchangeable Head, 0.35-2.5mm (VAS 1978/1-1)
• Exchangeable head, 4.0-6.0 mm² (VAS 1978/2 A )
- Slide the crimp connector onto the vehicle-specific single wire at one side and onto repair wire at the other side.
- Crimp the crimp connection at both wire ends using crimp pliers.
- Repeat this procedure on the other wire ends.
• Do not crimp wire insulation.
After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.
- Put Shrink Tip For Hot Air Gun (VAS 1978/15) on to Hot Air Gun, 220 V/ 50 Hz (VAS 1978/14).
CAUTION!
Risk of damaging surrounding components.
• When heat-shrinking crimp connections, be careful not to damage any other wiring, plastic parts or insulating material with the hot nozzle of the hot air gun.
• Always observe operating instructions of heat gun.
- Heat crimp connection using hot air gun lengthwise from center outward until it is sealed completely and adhesive comes out the ends.
• This is how the completed repair location with the inserted wire and two crimp connectors should look.
• Make sure that crimp connections do not lie directly next to each other when several wires need to be repaired. Arrange the crimp connectors at a slight offset so that the circumference of the wiring harness does not become too large.
• If the repair point was previous taped, this point must be taped again with yellow insulating tape after repairs.
• Secure the repaired wiring harness if necessary with a cable tie to prevent flapping noises while driving.