Wire Break With Single Repair Point

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Fig 1: Identifying Single Crimp Connection

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

-- If required, remove wiring harness wrapping using a folding knife.

-- Cut out the damaged section of wire using the Wiring Harness Repair Set - Wire Strippers VAS 1978/3.

Fig 2: Cutting Wire

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NOTE: If, by cutting out the damaged wire section, both ends of the vehicle-specific single wire are too short for a repair using a single crimp connector, insert a repair wire section of matching length with two crimp connectors, refer to WIRE BREAK WITH DUAL REPAIR POINT .

-- Strip the wire ends 6 to 7 mm using the Wiring Harness Repair Set - Wire Strippers VAS 1978/3.

Fig 3: Identifying Stripping Pliers To Strip Wiring Insulation

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-- Slide the crimp connector onto both stripped wire ends of the vehicle-specific single wire and crimp them using the Crimping Pliers -.35-2.5 mm VAS 1978/1A.

Fig 4: Crimping A Single Break Point

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NOTE:

Always be sure to use the correct crimping slot for the crimping connection used.

Do not crimp wire insulation.

After crimping, the crimp connectors must be heat-shrunk using the Wiring Harness Repair Set - Hot Air Blower VAS 1978/14A to prevent moisture penetration.

-- Place the Wiring Harness Repair - Blower - Shrink Element VAS 1978/15A on the Wiring Harness Repair Set - Hot Air Blower VAS 1978/14A.

-- Heat the crimp connector using the Wiring Harness Repair Set - Hot Air Blower VAS 1978/14A lengthwise from the center outward until it is sealed completely and the adhesive comes out at the ends.

Fig 5: Heating 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 Wiring Harness Repair Set - Hot Air Blower VAS 1978/14A.

Always follow the Wiring Harness Repair Set - Hot Air Blower VAS 1978/14A Operating Instructions!

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 with a cable tie to prevent flapping noises while driving.