0.35 mm 2 Wire or Greater With Individual Crimp Connector, 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.

0.35 mm 2 Wire or Greater 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.

• 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 Wire or Greater with Intermediate Wire Section, Repairing ]. 0.35 mm 2 Wire 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 the pliers and squeeze the pliers completely.

- Open the pliers again and remove the stripped wire end.

- For the repair, use a suitable crimp connector form the (VAS 1978 B).

- Use the (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 (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 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.