Wire, 0.35 mm and Larger With Individual Crimp Connector, 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 and Larger with Individual Crimp Connector, Repairing
Procedure
- Free up the wire to be repaired 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.
- Cut out the damaged wire section using wire stripper (VAS 1978/3).
• If, by cutting out the damaged wire section, both ends of the vehicle-specific single wire are too short for a repair using a single crimp connector, insert a repair wire section of matching length with two crimp connections => [ Wire, 0.35 mm or Larger with Intermediate Wire Section, Repairing ].
- 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 wire end from front up to stop into jaws of pliers and squeeze the pliers completely.
- Open pliers again and remove the stripped wire end.
- For the repair, use a suitable crimp connector 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 crimp connection on to both stripped wire ends of vehicle-specific single wire and crimp them using crimp pliers.
• 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 individual crimp connector should appear.
• 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.