Repairs Using Crimp Connectors

Repair Kit IV For Vehicle Electronics 61 9 020:

- Various kits are available for repairing the wiring harness.




- Example: Repair set A for contact sleeves on fan connectors.




Select repair set and remove following parts:
1. Prepackaged end of cable with requisite wire cross section
2. Crimp connector for selected wire cross section
3. Shrink-fit hose




- Unlock housing and eject damaged contact (4) Replacing - Repairing Connectors - - Refer To Replacing - Repairing Connectors.
- Mark damaged contact (4) with socket number of housing and press it out at housing using relevant special tool contained in special tool kit 61 1 150.




- Cut off wire with faulty contact (5) at point which is easily accessible.

CAUTION: Check maximum length of repair cable!

NOTE: It more than one wire has to be repaired cuts of wire ends must be arranged offset so that wiring harness will not be too thick at repaired point.




- Strip wiring-harness wire end (6).




- Cut prepackaged end of cable (7)to length and strip Insulation.




- Crimp connector onto prepackaged end of cable.




- Install shrink-on sleeve (8) on unused wire end.




- Crimp unused wire end to butt connector.




- Pull shrink-on sleeve over butt connector.




- With hot air blower, shrink the shrink-on sleeve on both sides (9) of shrink-fit hose until cement emerges uniformly all round.

CAUTION: Do not burn shrink-on sleeve.

- Install contact in housing.