Wire Break With Dual Repair Point

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Wire Break With Dual Repair Point

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-- Free up the wire to be repaired at two places (approximately 20 cm on both sides of the respective repair point).

-- Remove wiring harness wrapping using a folding knife.

-- Place the yellow repair wire next to the damaged wiring harness and cut the repair wire to the required length using the Wiring Harness Repair Set - Wire Strippers VAS 1978/3.

Fig 2: Cutting Wire

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

-- 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 crimp connection onto vehicle-specific single wire at one side and onto repair wire at the other side.

-- Crimp the crimp connector at both wire ends using the Crimping Pliers -.35-2.5mm VAS 1978/1A.

Fig 4: 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.

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.