Vehicle Electrical System, Repair Information
Vehicle Electrical System, Repair Information
When disconnecting and connecting the battery, the procedure must be followed as described in the Repair Information
Some tools are supplied with a tool safety clip, which is slid over the tool points after using the tool, in order to protect other workers from injuries and tool points from damage.
• When performing repairs, always heed any notes, cautions and warnings found in the applicable repair information.
• Pay attention the country-specific requirements.
• Disconnect the battery before working on the electrical system. Refer to. By disconnecting the battery (current disruption), the electrical system is guaranteed to be safe to work on. The positive battery wire only has to be disconnected to remove the battery.
• Before commencing repair work, always eliminate cause of damage, for example, sharp body edges, faulty components, corrosion etc.
• Further information, such as, installing and removing the individual components can be found in the appropriate Repair Information.
• Soldering is not permissible for repairs to the vehicle electrical system.
• Wiring harness and connector repairs to vehicle electrical system must only be performed using Wiring Harness Repair Set (VAS 1978) / Wiring Harness Repair Set (VAS 1978A) / Wiring Harness Repair Set (VAS 1978B).
• Exclusive use is to be made of yellow wires for wiring harness repairs.
• Wiring harness repairs may not be performed again in the wrapping of the vehicle-specific wiring harness and are to be marked with yellow adhesive tape.
• These yellow wires and every location on wiring harness wrapped in yellow insulating tape indicates a previous repair.
• Crimp connections must never be repaired. Route a wire parallel to the faulty wire.
• After crimping, crimp connections must be heat-shrunk using Hot Air Blower (VAS 1978/14) to prevent moisture penetration.
• Always observe also the supplementary notes for repairing wiring harnesses on airbag- and seat belt tensioner systems, fiber optic cables, CAN-Bus wires, antenna wires and wire cross-sections up to 0.35 mm2, refer to => [ Wires with Diameter up to 0.35 mm, Repairing ] Wires with Diameter up to 0.35 mm2, Repairing.
• A function test must be performed after every repair. If necessary, check DTC memory, erase and/or bring systems into basic setting.
• If possible, do not loosen grounding straps from the body (danger of corrosion).
• All the wire cross-sections not in the vehicle are contained in the Wiring Harness Repair Set (VAS 1978B) and previous versions. If the required wire cross-section is not present, the next greater cross-section must be used.
• Shielded harnesses may not be repaired. If faulty, the entire harness must be replaced.
• Heat-resistant wires have been installed in the vehicle at various locations, mainly in the engine compartment. Heat-resistant wires can be recognized by their somewhat duller and softer insulation. Only heat-resistant wires may be used to repair these wires.