0.35 mm2 or Greater With Intermediate Wire Section, Repairing

0.35 mm2 Or Greater With Intermediate Wire Section, 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.

• 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.

Risk of damaging the electrical wires.

• Expose 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 (VAS 1978/3) 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 (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 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.






- 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 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.