Tool Descriptions

Crimp Pliers with Insert

Fig 1: Crimping Pliers

Courtesy of VOLKSWAGEN UNITED STATES, INC.

The crimping pliers without insert VAS 1978/1, ith insert For Crimping Pliers VAS1978/2, s component of Wiring Harness Repair Kit VAS1978 and is used to crimp the crimp connection during wiring harness repair.

Crimp connection color	Crimping slot color	Wire cross-section
yellow	yellow	0.35 mm ²
red	red	0.5 mm ² - 1.0 mm ²
blue	blue	1.5 mm ² -2.5 mm ²
yellow	yellow	4.0 mm ² -6.0 mm ²

NOTE:

Crimping Pliers (Base Tool) VAS1978/1-2 in conjunction with Exchangeable Head, 0.35-2.5mm VAS1978/1-1 or Head Adapter 4.0-6.0mm^2 VAS1978/2A can also be used to crimp the connections as an alternative.
Always be sure to use the correct crimping slot for the crimping connection used.
Do not crimp wire insulation.

Terminal Release Tools

Fig 2: Terminal Release Tool

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Various release tools are used to remove the different terminals from terminal housings without damage.

A selection of release tools is a component of Wiring Harness Repair Kit VAS1978 and of Wiring Harness Repair Set VAS1978A. Release Tool Set VAS1978/35 contains the entire set of release tools.

CAUTION: Some tools are supplied with a tool safety clip, which is slid over the tool points after using the tool, in order to protect other workers from injuries and tool points from damage.

Releasing and disassembling terminal housings → Terminal Housings, Releasing and Disassembling .

Single Wire Seal Assembly Tools

Fig 3: Terminal Assembly Tool

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Assembly tools allow single wire seals to be slid into terminal housing up to stop without damage, this achieves a complete seal between single wire and terminal housing.

Four assembly tools for single wire seals are components of Wiring Harness Repair Kit VAS1978 and of Wiring Harness Repair Set VAS1978A.

Assembly of single wire seals.

Wire Stripper VAS 1978/3

Fig 4: Wire Stripper (VAS1978/3)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Wire Stripper VAS1978/3 is used for professional stripping and cutting of wires.

Wire Stripper VAS1978/3 is a component of Wiring Harness Repair Kit VAS1978 and of Wiring Harness Repair Set VAS1978A.

Wire stripper has an adjustable stop in its pliers-jaws which can be set to the desired length of wire insulation to be removed.

Stripping

Set the slideable stop in pliers-jaws to the desired length dimension to be stripped.

Fig 5: Stripping Insulation At Wiring Using Stripping Pliers

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert wire end from front up to stop into jaws of pliers and squeeze the pliers completely.
Open pliers again and remove the stripped wire end.

Fig 6: Cutting Wire

Courtesy of VOLKSWAGEN UNITED STATES, INC.

If necessary, cut wires using side-cutter function on the top of the wire stripper.

Fig 7: Hot Air Gun (VAS1978/14)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Hot Air Gun VAS 1978/14

CAUTION:

When heat-shrinking crimp connections, do not damage any other wiring, plastic parts or insulating material with the hot air gun nozzle.
Always observe operating instructions of heat gun.

Hot Air Gun VAS1978/14 is used in conjunction with Shrink Tip For Hot Air Gun VAS1978/15 to heat-shrink the crimp connections. After crimping, heat-shrink crimp connections using hot air gun to prevent moisture penetration.

Hot Air Gun VAS1978/14 is a component of Wiring Harness Repair Kit VAS1978 and of Wiring Harness Repair Set VAS1978A.

Heat-shrinking crimp connections using Hot Air Gun VAS1978/14, r.

Crimping Pliers 0.35-2.5 mm ^2 VAS 1978/1A