Release Tool Set

Wiring Harnesses and Connectors, Repairing

Safety Precautions

CAUTION!
When performing repairs on airbag and seat belt tensioner wiring harness, use only terminals, connectors and wires designated for it.

CAUTION!
Be sure to read the information regarding repairing the wiring harnesses for the airbag and pretensioner.

Observe country-specific regulations.

Pay attention to decals designating high voltage components. When performing repairs, residual voltage must be discharged.

The wiring harnesses for the airbag and the pretensioner may be repaired only with the (VAS 1978 B). Refer to => [ Airbag and Belt Tensioner Wires, Repairing ]. Airbag and Belt Tensioner Wires, Repairing

Refer to User's instructions of (VAS 1978 B)

Release Tool Set

Release Tool Set (VAS 1978/35)

• Connector release tool applications for various connector locking systems are listed in a table in VAS 1978/35 Instruction manual or refer to accompanying CD (where applicable).

CAUTION!
Observe the current notes in the corresponding Repair Information for all repairs.

Before commencing repair work, always eliminate cause of damage, e.g. sharp body edges, faulty components, corrosion etc.

For additional information concerning repairs, for example, component removal and installation, always refer to the applicable Repair Information.

Exclusive use is to be made of yellow wires for wiring harness repairs. These yellow wires and every location on wiring harness wrapped in yellow insulating tape indicates a previous repair.

A function test must be performed after every repair. Where applicable, check the system DTC memory and bring system into Basic Setting.

Some tools utilize a security device which must be placed over the working part of the tool after use in order to protect the tool tip against damage, as well as prevent user injury.

Secondary Connector Locks

• The secondary lock is a housing securing mechanism (second locking mechanism) that secures all wires in one terminal housing. If a secondary lock is installed at a terminal housing, it must always be opened or removed using specified tool before releasing and pulling out individual crimp contacts.

• Secondary lock is distinguished by a different color from the rest of the contact housing. It simplifies recognizing the secondary lock and clarifies its function.

• The shapes of the terminal housings depicted here are only a selection which, as an example, should make clear the various functions of the secondary lock.

Example 1:

Connector lock released by removing "cam" - arrow -.

Example 2:

Connector lock released by opening "flap" - arrow -.

Example 3:

Connector lock released by moving "slider" - arrow -.

Primary Connector Locks

Primary connector locks pertain to the retention of electrical terminal pins in the connector housing.

The shapes of the primary locks depicted in the following are only a selection which, as an example, should make clear the various functions of the secondary lock.

Flat Connector System

• If necessary, housing securing mechanisms (secondary locks) must be released or removed using specified tool before releasing the contacts.

Connector with One Locking Tab

- Guide the release tool which fits the terminal housing into release channel on terminal housing.

- Unlock terminal by pushing terminal towards release tool - arrow - while pushing release tool towards terminal housing.

• By pushing the contact in the direction of the terminal housing, the contact retaining tab is lifted off the housing shoulder and can be released using the release tool.

- At the same time, push the release tool in the direction of the terminal housing and pull the released contact out of the terminal housing - arrow -.

- Remove the release tool after removing the contact from the housing.

Connector with Two Locking Tabs

- Guide the release tool which fits the terminal housing into release channel on terminal housing.

- Grasp contact at wire and push it gently into terminal housing until it stops - arrow -.

• By pushing the contact in the direction of the terminal housing, contact retaining tabs are lifted off the housing shoulder and can be released using the release tool.

- At the same time, push the release tool in the direction of the terminal housing and pull the released contact out of the terminal housing - arrow -.

- Remove the release tool after removing the contact from the housing.

Asymmetrical Connector

- Guide the release tool which fits the terminal housing into release channel on terminal housing.

- Grasp contact at wire and push it gently into terminal housing - arrow -.

- Remove the release tool after removing the contact from the housing.

Round Connector Systems

Where applicable, release or remove secondary connector lock with proper tool.

- Guide the release tool which fits the terminal housing into release channel on terminal housing.

- Grasp the contact at the wire and gently push it into the terminal housing - left arrow -.

• By pushing the contact in the direction of the terminal housing, contact retaining tabs are lifted off the housing shoulder and can be released using the release tool.

- At the same time, push the release tool in the direction of the terminal housing - right arrow - and pull the released contact out of the terminal housing.

- Remove the release tool after removing the contact from the housing.

Special Connector Systems

• If necessary, housing securing mechanisms (secondary locks) must be released or removed using specified tool before releasing the contacts.

Faston Contact

- Guide the release tool that fits the terminal housing into the release channel on the terminal housing - arrow -.

- Grasp contact at wire and push it gently into terminal housing.

• By pushing the contact in the direction of the terminal housing, contact retaining tabs are lifted off the housing shoulder and can be released using the release tool.

- At the same time, push release tool in direction of terminal housing and pull the released contact out of terminal housing - arrow -.

- Remove the release tool after removing the contact from the housing.

GT 150/280 Contacts

- Guide the release tool which fits the terminal housing under retaining tab into terminal housing.

- Push tool into terminal housing until it stops - arrow -.

Terminal is released.

- Remove the release tool after removing the contact from the housing.

Contacts without Retaining Tabs

- Insert release tool under retaining tab of terminal housing.

- Push release tool through until it stops by gently lifting - arrow -.

- Remove released terminal.

- Remove the release tool after removing the contact from the housing.

Connection Aids

- Install the wire in direction of arrow into the groove on the (VAS 1978/10A) up to the end of the contact.

- Pull the cable - arrow - all the way to the end.

- Insert tool with cable into connector housing from rear until terminal locks into place.

• Intended for terminals with and without "seals".