Wiring Harnesses, Repair Information

Wiring Harnesses, Repair Information

• Observe general notes for repairs on the vehicle electrical system => [ Vehicle Electrical System, Repair Information ] Vehicle Electrical System, Repair Information.

• Not all the wire cross-sections installed in the vehicle are contained in the Wiring Harness Repair Set (VAS 1978) or Wiring Harness Repair Set (VAS 1978A). If the required wire cross-section is not present, the next greater cross-section must be used.

• Wiring harness and connector repairs to vehicle electrical system must only be performed using Wiring Harness Repair Set (VAS 1978) or Wiring Harness Repair Set (VAS 1978A).

• Soldering is not permissible for repairs to the vehicle electrical system.

• 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.

• 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.

• 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 wires with cross-sections up to 0.35 mm2.