0.25 mm 2 Wire With Intermediate Wire Section, Repairing
Wiring Harnesses and Connectors, Repairing
Special tools, testers and auxiliary items required
• Wiring Harness Repair Set (VAS 1978 B)
CAUTION!
• 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 (VAS 1978 B) is described in detail in the attached operating instructions.
• Repairs on open circuits and faulty connectors are also explained using examples.
0.25 mm 2 Wire with Intermediate Wire Section, Repairing
• Only 0.5 mm2 repair wires are available for repairing a 0.25 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.
• 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 12 to 14 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 the pliers again and remove the stripped wire end.
- Twist bare strands one-half turn.
- Repeat the procedure on the other end of the vehicle specific individual wire.
- Adjust the sliding stop in the (VAS 1978/3) jaws to 6 to 7 mm for the wire to be stripped.
- Insert the yellow repair 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 this procedure on the other repair wire end.
- For the repair of a 0.25 mm 2 wire, use a small yellow crimp connector from the (VAS 1978 B).
- To press the crimp connector, use the (VAS 1978/1-2) with (VAS 1978/1-1) from the (VAS 1978 B).
- Slide the small yellow crimp connector onto the vehicle-specific single wire at one side and onto the repair wire at the other side.
- Crimp the crimp connection at both wire ends using crimp pliers.
- Repeat this procedure at the other repair wire end.
• Do not crimp wire insulation.
After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.
- Place the (VAS 1978/15A) on the (VAS 1978/14A).
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 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.