Wire Break With Dual Repair Point

WARNING: This page is about a different variant/trim than selected.

Repair point with intermediate wire section

Fig 1: Identifying Wire Break With Dual Repair Point

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

-- If required, 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 wire stripper -VAS 1978/3-.

Fig 2: Identifying Wire Stripper To Cut Wire

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

-- Strip wire ends using 0.25 inch (6 - 7 mm) wire stripper.

Fig 3: Identifying Stripping Pliers To Strip Wiring Insulation

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-- 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 crimp pliers.

Fig 4: Identifying Crimping A Single Break Point

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-- Repeat this procedure at the other repair wire end.

NOTE:

Always be sure to use the correct crimping slot for the crimping connection used. Refer to CRIMPING PLIERS WITH INSERT .

Do not crimp wire insulation.

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

-- Put Shrink Tip For Hot Air Gun -VAS 1978/15- onto Hot Air Gun, 220 V/ 50 Hz -VAS 1978/14-.

-- Heat crimp connection using hot air gun lengthwise from center outward until it is sealed completely and adhesive comes out the ends.

Fig 5: Identifying Heating Of Crimp Connection Using Hot Air Gun

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CAUTION:

When heat-shrinking crimp connections, be careful not to damage any other wiring, plastic parts or insulating material with the hot nozzle of the hot air gun.

Always observe operating instructions of heat gun.

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 6: Identifying Offset Positions Of Crimped Connections

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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 if necessary with a cable tie to prevent flapping noises while driving.