Wires With Cross Section Up To 0.35 mm 2, Repairing

When repairing wires with a cross-section up to 0.35 mm² , new contacts must always be crimped on using the Crimping Pliers - JPT VAS 1978/9A or the Wiring Harness Repair - Crimping Plier - Base Tool VAS 1978/1-2 with the Wiring Harness Repair Set - Crimping Head - JPT VAS 1978/9-1 installed. Due to the low current strengths of these wires in the micro- to milli- range, contacts crimped on incorrectly lead to continuity resistances and cause malfunctions or failure of the respective system. The most frequent applications of these contacts are:

• Heated Oxygen Sensor
• RPM sensor
• Mass Airflow Sensor

By using the Crimping Pliers - JPT VAS 1978/9A or the Wiring Harness Repair - Crimping Plier - Base Tool VAS 1978/1-2 with the Wiring Harness Repair Set - Crimping Head - JPT VAS 1978/9-1 installed, the correct connection between crimp contact, wire and single wire seal is guaranteed. The tool is to be used only for the purpose described.

Crimping a new contact with single wire seal

-- Insert the Wiring Harness Repair Set - Crimping Head - JPT VAS 1978/9-1 into the Wiring Harness Repair - Crimping Plier - Base Tool VAS 1978/1-2, refer to CRIMPING PLIERS -.35-2.5mm VAS 1978/1A .

-- Place the single wire seal onto the repair wire.

Fig 1: Identifying Single Wire Seal Placed On Repair Wire

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-- Open the Wiring Harness Repair - Crimping Plier - Base Tool VAS 1978/1-2 (green body) and insert the repair wire end into the stripping slot of the Wiring Harness Repair - Crimping Plier - Base Tool VAS 1978/1-2.

Fig 2: Identifying Wiring Inserted In Crimping Pliers

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-- Close the Wiring Harness Repair - Crimping Plier - Base Tool VAS 1978/1-2 completely.

Fig 3: Identifying Stripping Wire

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-- Reopen the Wiring Harness Repair - Crimping Plier - Base Tool VAS 1978/1-2 and remove the stripped wire end.

-- Slide single wire seal in direction of stripped wire end until it rests flush with the wire insulation.

Fig 4: Identifying Position Of Single Wire Seal

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-- Insert the new crimp contact into the Wiring Harness Repair - Crimping Plier - Base Tool VAS 1978/1-2 mount.

Fig 5: Identifying Placement Of Crimp Terminal In Crimping Pliers

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-- Insert the stripped wire end with positioned single wire seal into crimp contact until it makes contact on "Wire-Stop".

Fig 6: Identifying Insertion Of Stripped Wire In Crimping Tool

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-- Crimp the contact, wire and single wire seal by completely closing the Wiring Harness Repair - Crimping Plier - Base Tool VAS 1978/1-2.

-- Reopen the Wiring Harness Repair - Crimping Plier - Base Tool VAS 1978/1-2 and remove the finished crimped-on contact.

A correctly performed crimp is distinguished by a clean compression of wire and single wire seal in the contact and has an impression on the rear side which identifies that the crimp was performed by a professional using the correct tool.

Fig 7: Correctly Performed Crimp

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