Repair of a 0.22 mm 2 or 0.35 mm 2 wire connection

NOTE:

Wiring harness repair kit VAS 1978 includes repair wires of three different thickness (0.5 mm ² , 1.5 mm ² , 4.0 mm ² ) and the corresponding crimp connectors.
Use 0.5 mm ² repair wire to repair a 0.35 mm ² wire.

Fig 1: Stripping Insulation At Wiring Using Stripping Pliers

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Perform repair as follows:

Strip off wire ends of 0.22 mm ² or 0.35 mm ² wire using wire stripper VAS 1978/3 (12 14 mm).
Fold up stripped wire ends half way.
Strip off ends of 0.5 mm ² wire using wire stripper (6 7 mm).

Fig 2: Crimping On Both Sides With Crimping Pliers

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Push crimp connectors over wire ends and crimp at both sides with crimping pliers without insert VAS 1978/1.

NOTE:

Be sure to use the correct red crimp insert for VAS1978/1 VAS 1978/24 for 0.5 mm ² wires.
Do not crimp insulation at end of wire.

Fig 3: Heating Crimp Connection Using Hot Air Gun

Courtesy of VOLKSWAGEN UNITED STATES, INC.

After crimping, crimp connector must be shrunk using hot air gun VAS 1978/14 and shrink tip for hot air gun VAS 1978/15.

Heat crimp connector from center outward until it is completely sealed and adhesive oozes out.
Adjust hot air blower to appropriate temperature according to instructions.
When shrinking make absolutely sure not to damage any other wiring, plastic parts or insulating material with the hot nozzle.
If wire was originally wrapped, wrap it again using yellow insulating tape. If necessary, secure wiring using new cable ties.