Contacts in Contact Housing, Repairing

Contacts in Contact Housing, Repairing

Special tools, testers and auxiliary items required

• Wiring Harness Repair Set (VAS 1978)

• Wiring Harness Repair Set (VAS 1978A)

• Wiring Harness Repair Set (VAS 1978 B)

• Crimp Pliers 0.35 mm2 - 2.5 mm2 (VAS 1978/1A)

• Wire Stripper (VAS 1978/3)

Procedure

- First, open or release the secondary lock of the contact housing, refer to => [ Secondary Lock ] Secondary Lock.

- Release contact (primary lock) using the appropriate release tool, refer to => [ Primary Lock ] Primary Lock.






- Pull contact at single wire out of contact housing.

- Take the yellow repair wire with the correct contact out of the (VAS 1978) / (VAS 1978A) / (VAS 1978 B).

- Free up the wire to be repaired approximately 20 cm (8 inches) on both sides of the repair point.

- Remove wiring harness wrapping using a folding knife.

- Insert new contact of repair wire into contact housing until it engages.






- Slide a single wire seal onto the repair wire.

• When doing this, small diameter of single seal must point toward contact housing.

- Slide single wire seal into contact housing using the correct assembly tool, refer to => [ Single Wire Seals, Installing ] Single Wire Seals, Installing.

- Shorten repair wire and single wire of vehicle-specific wiring harness according to your needs using (VAS 1978/3).






- Strip ends of repair wire and of vehicle-specific single wire using 6 - 7 mm (VAS 1978/3).






- Crimp the stripped ends of repair wire and single wire of vehicle-specific wiring harness using (VAS 1978/1A) and a crimp connection as described in=> [ Wire Break with Single Repair Point ] Wire Break with Single Repair Point.

• Make sure that crimp connections do not lie directly next to each other when several wires need to be repaired. Arrange crimp connections at a slight offset so that the circumference of the wiring harness does not become too large.






• In the event the repair point was previous taped, this point must be taped anew with yellow insulating tape after repairs.

• Secure the repaired wiring harness with a cable tie to prevent flapping noises while driving.