0.13 Mm2/0.35 Mm2/0.5 Mm2 Wire With Separate Crimp Connector, Repairing

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Special tools and workshop equipment required

Wiring Harness Repair Set - Hot Air Blower:VAS1978/14A from the Wiring Harness Repair Set:VAS1978B

Fig 1: Identifying VAS 1978 B
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Wiring Harness Repair - Crimping Plier - Base Tool:VAS1978/1-2 from Wiring Harness Repair Set:VAS1978B
Wiring Harness Repair - Interchangeable Head:VAS1978/1-3

NOTE:

Observe general notes for repairs on the vehicle electrical system. Refer to VEHICLE ELECTRICAL SYSTEM, GENERAL REPAIR INFORMATION .

For the repair there are repair wires with a 0.35 mm² and 0.5 mm² cross section.

Procedure

-- Install the Wiring Harness Repair - Interchangeable Head:VAS1978/1-3 -1- as follows on the Wiring Harness Repair - Crimping Plier - Base Tool:VAS1978/1-2 :

-- Open the Wiring Harness Repair - Crimping Plier - Base Tool:VAS1978/1-2 .

-- Remove the locking pin -2- all the way in the direction of the -arrow A-.

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-- Insert the Wiring Harness Repair - Interchangeable Head:VAS1978/1-3 -1- in the direction of the -arrow B- centered in the Wiring Harness Repair - Crimping Plier - Base Tool:VAS1978/1-2 .

-- Push back in the locking pin -2- all the way.

-- Free up the wire to be repaired approximately 20 cm (7.87 in.) on both sides of the repair point.

CAUTION:

Risk of damaging the wires.

Expose wrapped wiring harnesses carefully

-- If necessary remove the wiring harness wrapping.

-- Cut out the damaged wire section using a cutting wire.

NOTE:

When both ends of the vehicle-specific single wire are too short after cutting out the damaged wire section for a repair with a separate crimp connector, insert a corresponding long piece of yellow repair wire with two crimp connectors.

When repairing the single wire with crimped on/connected contact place the yellow repair wire near the damaged vehicle-specific single wire and cut to the required length.

-- Insert the wire end -2- all the way -arrow- in the cross section fitting mount on the Wiring Harness Repair - Interchangeable Head:VAS1978/1-3 -1-.

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-- Completely push together the crimping pliers and hold them together.

-- Remove the wire end -2- from the Wiring Harness Repair - Interchangeable Head:VAS1978/1-3 -1- to strip.

-- Open the crimping pliers again.

The insulation must be cut cleanly and removed from the wires.
No insulation can remain on bare wires.
The single wires must not be damaged.

-- Use the small transparent crimp connector from the Wiring Harness Repair Set:VAS1978B .

-- For 0.31 mm² wires additionally push a heat-shrinkable tube on the wires. Refer to the Parts Information.

-- Push the crimp connector -2- all the way in the direction of the -arrow A- in the clamp opening on the Wiring Harness Repair - Interchangeable Head:VAS1978/1-3 .

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-- Push the striped wire -1- in the direction of the -arrow B- in the crimp connector -2-.

All single wires must be pushed in the crimp connector -2-
Do not crimp wire insulation -arrow C-.

-- Push the crimping pliers completely together and then open.

-- Remove the wire with the crimp connector.

-- Repeat the wire crimping with the crimp connector on the other side as described.

-- Remove the locking pin -1- all the way in the direction of the -arrow A-.

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-- Pivot the upper section on the Wiring Harness Repair - Interchangeable Head:VAS1978/1-3 -2- in the direction of the -arrow B-.

-- Remove the crimped crimp connector.

Correct Crimping Results

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-- After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.

On 0.31 mm² wires and additional heat-shrinkable tube must be heat-shrunk to ensure a complete seal.

-- Insert the Wiring Harness Repair - Blower - Shrink Element:VAS1978/15A on the Wiring Harness Repair Set - Hot Air Blower:VAS1978/14A .

Fig 2: Heating Crimp Connection Using Hot Air Gun

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CAUTION:

Risk of damaging the wires.

When heat-shrinking the heat-shrinkable tube, be careful not to damage any other wiring, plastic parts or insulating material with the hot nozzle of the hot air blower.
Always observe operating instructions of heat gun.

-- For 0.13 mm² wires position the heat-shrinkable tube -1- by feeling the contours centered over the crimp connector -2-.

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The dimension -a- must be approximately the same on both sides.

-- Heat the heat-shrinkable tube/crimp connector using the hot air blower lengthwise from center outward until it is sealed completely and adhesive comes out the ends.

The completed repair location -3- must look like so.

NOTE:

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

Fig 3: Identifying Offset Positions Of Crimped Connections

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If the repair point was previous taped, this point must be taped again with yellow insulating tape after repairs.

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

Early Release

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-- Push the operating lever -1- upward in the direction of the -arrow A-.

-- At the same time push the crimping pliers together and then open.

CAUTION:

Do not use the crimp connector after it is early released.