Wires with Diameter Up To 0.35 mm 2, Repairing

Wires with Diameter Up To 0.35 mm 2, Repairing

Special tools, testers and auxiliary items required

• Crimping pliers, complete (VAS 1978/1 A)

• Exchange head, 0.35mm2 - 2.5mm2 (VAS 1978/1-1)






When repairing wires with a cross-section up to 0.35 mm2, new contacts must always be crimped on using Crimping Pliers of JPT Contacts (VAS 1978/9A) , or Crimping Pliers (Base Tool) (VAS 1978/1-2) with Head Adapter for JPT Contacts (VAS 1978/9-1) installed. Due to the low current strengths of these wires in the micro- to milli- range, contacts crimped on incorrectly lead to continuity resistances and cause malfunctions or failure of the respective system. The most frequent applications of these contacts are:

• Heated oxygen sensor (HO2S)

• Speed (RPM) sensor

• Mass Air Flow (MAF) Sensor

By using Crimping Pliers of JPT Contacts (VAS 1978/9A) or Crimping Pliers (Base Tool) (VAS 1978/1-2) with Head Adapter For JPT Contacts (VAS 1978/9-1) installed, correct connection between crimp contact, wire and single wire seal is guaranteed. The tool is to be used only for the purpose described.

• Contacts in a normal and a gold-plated version are crimped onto repair wires. The same version of the contact that was installed at the factory must always be used for repairs.

Crimping A New Contact With Single Wire Seal

- Insert exchangeable head for JPT contact (VAS 1978/9-1) into crimp pliers (basic tool) (VAS 1978/1-2). Refer to => [ Crimping Pliers ] Crimping Pliers (VAS 1978/1A).

- Place the single wire seal onto the repair wire.






• When doing this, the smaller diameter of single wire seal must be facing in the direction of the contact to be crimped on.

- Open crimp pliers and place the repair wire end into stripping slot of crimp pliers.






- Close crimp pliers completely.






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

- Slide single wire seal in direction of stripped wire end until it rests flush with the wire insulation.






- Place new crimp contact into mount on crimp pliers.






- Insert the stripped wire end with positioned single wire seal into crimp contact until it makes contact on "wire stop".






- Crimp the contact, wire and single wire seal by closing crimp pliers completely.

- Open crimp pliers again and remove the finished crimped-on contact.

A correctly performed crimp is distinguished by a clean compression of wire and single wire seal in the contact and has an impression on the rear side which identifies that the crimp was performed by a professional using the correct tool.