Wire Break with Dual Repair Point

Wire Break with Dual Repair Point

Special tools, testers and auxiliary items required

• Wire Stripper (VAS 1978/3)

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

• Hot Air Blower (VAS 1978/14A)

• Shrink Element For Hot Air Blower (VAS 1978/15)

Repair Point With Intermediate Wire Section





- Free up wire intended for repair at two points (approximately 20 cm (8 in.) to both sides of respective repair points).

- Remove wiring harness wrapping using a folding knife.

- Route yellow repair wire next to damaged wiring harness and cut repair wire to the required length using (VAS 1978/3).






- Cut damaged wire section from the vehicle-specific single wire.

- Strip 6 to 7 mm (0.25 in.) of insulation on the ends of the wires using the (VAS 1978/3).






- Slide crimp connection onto vehicle-specific single wire at one side and onto repair wire at the other side.

- Crimp the crimp connection at both wire ends using (VAS 1978/1A).






- Repeat this procedure at the other repair wire end.

• Always be sure to use the correct crimping slot for the crimping connection used. Refer to => [ Crimping Pliers with Insert ] Crimping Pliers with Insert.

• Do not crimp wire insulation.

After crimping, crimp connections must be heat-shrunk using the (VAS 1978/14A) to prevent moisture penetration.

- Put (VAS 1978/15) onto (VAS 1978/14A).

- Heat crimp connection using (VAS 1978/14A) lengthwise from center outward until it is sealed completely and adhesive comes out the ends.







When heat-shrinking crimp connections, be careful not to damage any other wiring, plastic parts or insulating material with the hot nozzle of the (VAS 1978/14A).

Always read the Operating Instructions that come with the (VAS 1978/14A) !

• 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.