0.35 mm 2 or Greater With Individual Crimp Connector, Repairing

0.35 mm 2 Or Greater With Individual Crimp Connector, Repairing

Special tools, testers and auxiliary items required

• Wiring Harness Repair Set VAS 1978/A (VAS 1978 B)

• Repairs to the wiring harnesses and connectors must only be performed using the Wiring harness repair set (VAS 1978 B).

• Observe the country-specific requirements.

• Use of the Wiring harness repair set (VAS 1978 B) is described in detail in the attached operating instructions.

• Repairs on open circuits and faulty connectors are also explained using examples.

Procedure

- Free up the wire to be repaired approximately 20 cm on both sides of the repair point.

Risk of damaging the electrical wires.

• Expose 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. Refer to=> [ 0.35 mm Or Greater With Intermediate Wire Section, Repairing ] 0.35 mm2 or Greater With Intermediate Wire Section, Repairing.

- Adjust the sliding stop in the (VAS 1978/3) 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 (VAS 1978 B).

- Use the crimping pliers (base tool) (VAS 1978/1-2) to press the crimp connector.






The following exchangeable heads are available for the (VAS 1978/1-2) :

• Exchange head, 0,35 mm2 - 2,5 mm2 (VAS 1978/1-1)

• Exchangeable head, 4.0-6.0 mm2 (VAS 1978/2 A)

- Slide crimp connection onto 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.






- Place the shrink element for hot air blower (VAS 1978/15A) on the hot air blower (VAS 1978/14A).

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 blower.

• Always observe operating instructions of heat gun.

- Heat crimp connection using the hot air blower 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.